instantlock 2 system scaffold component ... - nextgen

INSTANTLOCK 2 SYSTEM SCAFFOLD COMPONENT TECHNICAL MANUALEngineering Approval: Lance Smith Manual Release Date: 05/17/19Revision: B

C

CONTENTS

Introduction _____________________________________________________________________________ EIntended Use of InstantLock 2 System Scaffold _________________________________________________ F

BASES _________________________________________________________________________________________________InstantLock 2 Screw Jack ___________________________________________________________________1InstantLock 2 Swivel Jack __________________________________________________________________ 2InstantLock 2 Casters _____________________________________________________________________ 3

VERTICAL POSTS ________________________________________________________________________________________InstantLock 2 Vertical Post _________________________________________________________________ 4InstantLock 2 Vertical Post Loading __________________________________________________________ 5

HORIZONTAL BARS ______________________________________________________________________________________InstantLock 2 Horizontal Bar ________________________________________________________________ 6InstantLock 2 Horizontal Bar Loading _________________________________________________________ 8InstantLock 2 Horizontal Bar Loading ________________________________________________________ 9Bracing InstantLock 2 Horizontal Bars ________________________________________________________ 11InstantLock 2 Horizontal Bar with One (1) Brace ________________________________________________12InstantLock 2 Adjustable Bearer _____________________________________________________________14InstantLock 2 Adjustable Bearer Loading ______________________________________________________16

TRUSSES _______________________________________________________________________________________________InstantLock 2 Trusses _____________________________________________________________________18InstantLock 2 Truss Loading _______________________________________________________________ 20InstantLock 2 Lattice Girders_______________________________________________________________ 22

BRACING _______________________________________________________________________________________________InstantLock 2 Vertical Diagonal Brace _______________________________________________________ 23InstantLock 2 Diagonal Pin Brace __________________________________________________________ 24General Guidelines For Bracing InstantLock 2 _________________________________________________ 26

SIDE BRACKETS _________________________________________________________________________________________InstantLock 2 Side Brackets _______________________________________________________________ 28Wedge Lock Head Side Brackets ___________________________________________________________ 29

INTERMEDIATE HORIZONTAL ADAPTERS ____________________________________________________________________InstantLock 2 Intermediate Horizontal Adapters _______________________________________________ 30InstantLock 2 Short Intermediate Horizontal Adapters ___________________________________________31

DECKING _______________________________________________________________________________________________InstantLock 2 Metal Boards ________________________________________________________________ 32InstantLock 2 Wood Planks _______________________________________________________________ 33InstantLock 2 Filler Plates _________________________________________________________________ 35InstantLock 2 Duckbill Plank _______________________________________________________________ 36

FOUNDATION EQUIPMENT _________________________________________________________________________ 37

D

CONTENTS (CONT’D)

ACCESS ___________________________________________________________________________________________InstantLock 2 Ladder ____________________________________________________________________ 38InstantLock 2 Ladder Bracket ______________________________________________________________ 39InstantLock 2 Aluminum Ladder _____________________________________________________________ 40InstantLock 2 Snow Ladder _________________________________________________________________ 41InstantLock 2 Ladder Cage __________________________________________________________________ 42InstantLock 2 Right-Angle Brace ______________________________________________________________ 43InstantLock 2 Stair System __________________________________________________________________ 44InstantLock 2 Safety Gate __________________________________________________________________ 45InstantLock 2 Heavy-Duty Gate Post __________________________________________________________ 46InstantLock 2 Gate Adapter __________________________________________________________________ 47

ALUMINUM TOE BOARDS __________________________________________________________________________ 48

SPECIALTY CLAMPS ________________________________________________________________________________Rosette Clamp __________________________________________________________________________ 49Ring Lock Suspension Connector ___________________________________________________________ 50Twin Wedge Head ________________________________________________________________________51

TUBE AND CLAMP APPLICATION ______________________________________________________________________InstantLock 2 With Tube And Clamp ________________________________________________________ 53Hanging/Suspended Scaffold ______________________________________________________________ 56Cantilevered Scaffold _____________________________________________________________________ 59Adjustable Tube and Clamp Adapter _________________________________________________________61

FALL PROTECTION ANCHORAGE POINTS _______________________________________________________________InstantLock 2 as a Fall Protection Anchorage Point ____________________________________________ 62Davit Arm ______________________________________________________________________________ 65

MATERIAL TRANSPORT ______________________________________________________________________________InstantLock 2 Truss as a Lifting Rig __________________________________________________________ 66 Lifting and Moving Racked Material _________________________________________________________ 67InstantLock 2 Equipment Carts ____________________________________________________________ 69InstantLock 2 Skid Pan ___________________________________________________________________ 70

STORAGE RACKS ___________________________________________________________________________________InstantLock 2 Square Storage Rack ___________________________________________________________ 71InstantLock 2 Metal Board Storage Rack ______________________________________________________ 72InstantLock 2 Horizontal Storage Rack ________________________________________________________ 73InstantLock 2 Horizontal Storage Rack Support _________________________________________________ 74InstantLock 2 Storage Basket _______________________________________________________________ 75

ADDITIONAL INFORMATION __________________________________________________________________________OSHA Compliance of InstantLock 2 System Scaffold _____________________________________________ 76 InstantLock 2 Building Tips __________________________________________________________________ 79 Code of Safe Practices for InstantLock 2 _______________________________________________________ 82Scaffold and Access Industry Association Code of Safe Practices ___________________________________ 83Scaffold Inspection Guidelines _______________________________________________________________ 87Scaffold Material Loading and Shipping Guidelines ______________________________________________ 90InstantLock 2 End-User Repair Guidelines ______________________________________________________ 93General Assembly Instructions _______________________________________________________________ 94

E

INTRODUCTION

COMPATIBILITY OF INSTANTLOCK 2

InstantLock 2 System Scaffold is designed and engineered by Next Generation Scaffold (NextGen) to be compatible with pin and ring, and standard tube and clamp components (i.e., clamps, poles, ladders and ladder brackets) that are currently available within the scaffold industry.

These tube and clamp components are generally used:• As tie-offs when needed for seismic considerations.• When needed to transition horizontally to get

around obstacles.• When needed to transition vertically to get around

an interference.• As ladders and ladder brackets for access to work

platforms.• As needed for structural bracing and reinforcement.

GENERAL ERECTION CRITERIA

InstantLock 2 material is designed by engineers to comply with OSHA and CAL-OSHA specifications associated with supported system scaffolds, along with necessary tube and clamp criteria.

NextGen expects all InstantLock 2 users to:1. Abide by all Federal, State and local regulations

governing scaffold construction and use.2. Erect, modify or dismantle scaffolding using only

qualified and competent personnel with adequate supervision.

3. Provide competent and qualified supervision who can inspect and sign off on each scaffold before authorization is given for general use.

4. Follow common safety guidelines, including: pre-job briefings, procedure compliance, tagging, flagging, wearing of proper PPE, weight-loading restrictions, vertical leg placement, use of diagonal bracing, horizontal wraps, proper use of handrails, mid-rails, toe boards, safety netting, screw jacks, ladders, metal or wood decking, etc.

5. Obtain and follow engineered drawing(s) when required.

SPECIAL CONSIDERATIONS

Many InstantLock 2 scaffold components telescope, swivel, slide or hinge. Use caution when passing to other workers, transporting, and installing these items.

Ensure all items containing locks or pins are secured before handling, transporting, or passing these items to another worker.

STAGING PLATFORMS

• All staging platforms must have an engineer’s involvement.

• The scaffold must be analyzed in accordance with the InstantLock 2 System Scaffold Component Technical Manual to ensure all components are within the set limits.

• The maximum allowable load and criteria for the structure must be clearly marked at any/all entrances to the platform.

• All conditions must be clearly marked at the inspection tag and enforced to ensure overloading of the scaffold does not occur.

Shipping and Receiving: (832) 479-0779 | [email protected]

Engineering: (443) 293-6352 | [email protected]

Website: www.nextgenscaffold.com

All material must be inspected prior to use! See inspection guidelines on page 87.

F

INTENDED USE OF INSTANTLOCK 2 SYSTEM SCAFFOLD

1. Unless otherwise stated, all load data presented in this manual includes the OSHA 4:1 safety factor.

2. All load data presented in this manual is for downward or compressive loading only, unless otherwise stated.

3. InstantLock 2's scaffold material, when constructed for normal use, is not designed to be up- or side-loaded in excess of OSHA and ANSI requirements. When conditions require special loading, extra design features must be added to ensure proper stability.

4. Once installed and completed, scaffolding should be considered part of the customer’s plant equipment. Abuse or mistreatment of the scaffold material will not be tolerated.

5. The scaffold material should be inspected for damage and replaced after any incident which could affect the integrity of the scaffold material, such as:

• The scaffold comes into contact with any moving equipment, forklifts, trucks or trailers, and other types of mobile equipment.

• The scaffold is affected by an unintended load, flanges or piping attached to a crane or come-along, objects dropped from above or swung in from the side, fall arrest incident, etc.

• Excessive force is applied to the scaffold from abuse or accidental contact.

• The material is modified in any way with a torch, saw or other equipment.

• The material is affected from corrosive chemicals that remove the coating and/or damage the base metal.

• The material is bent or otherwise damaged.

6. The end-user is responsible for ensuring their competent and qualified individuals and scaffold erection personnel are trained and fully understand the above requirements.

7. All end-users must be trained in the proper use of InstantLock 2 System Scaffold. This tech manual is provided as a reference for training. New users should examine the InstantLock 2 Building Tips section at the end of this manual.

8. Field testing of scaffold components shall not be conducted. Testing will be performed only by the manufacturer.

9. OSHA requires that inspections must be made by the scaffold builder and end-user.


1


Revised: 05/17/19

INSTANTLOCK 2 SCREW JACK

PART # DESCRIPTION WEIGHT (LBS.)MAXIMUM ALLOWABLE

LOAD (LBS.)

FBJ Fixed Base Screw Jack 11.6 7,500

FBJ2 Fixed Base Caster Screw Jack 12.2 7,500

Third-party manufactured components. Data may vary.

12"MAX.

DISTANCEFROM BASE

20"

FIXED BASE SCREW JACK BASE PLATE

6"1/2" Dia. Holes

4"

6"3/8" Dia. Holes

6"

FIXED BASE CASTER SCREW JACK BASE PLATE

The fixed base caster screw jack has a larger base plate that is designed to allow the jack to be bolted to a standard flat top caster.

The fixed base caster screw jack also has added bracing to make it stronger while attached to a caster.

BUILD NOTES:

1. 7/16 x 1 1/2 inch, grade 5 or stronger bolts with flat washers must be used to bolt the caster to the fixed base caster screw jack.

2. Wood sills are to be used under leveling jacks in accordance with OSHA guidelines or plant safety regulations, whichever is stricter.

3. Wood sills should be properly sized to prevent overloading the substrate on which the scaffold is resting.

WARNING: Jack cannot be extended more than 12 inches above the base.

2


Revised: 05/17/19

PART # DESCRIPTION WEIGHT (LBS.)MAXIMUM ALLOWABLE LOAD (LBS.)LOAD (P) WHEN ANGLE OF SLOPE 0°

SBJ Swivel Base Screw Jack 7.5 5,000

INSTANTLOCK 2 SWIVEL JACK

SLOPED SURFACESHEAR FORCEANGLE OF

SLOPE

SWIVEL BASE SCREW JACK BASE PLATE

6"3/8" Dia. Holes

6"

Third-party manufactured component. Data may vary.

WARNING: Jack cannot be extended more than 12 inches above the base.

3


Revised: 05/17/19

INSTANTLOCK 2 CASTER

PART # DESCRIPTION WHEEL TYPEWEIGHT

(LBS.)ALLOWABLE ROLLING LOAD

(LBS.)

CR8 8" Caster with pin Plastic 17 900

CRF8 8" Caster flat base Plastic 17.5 900

CR12 12" Caster Plastic 23 1,300


BUILD NOTES:

1. Casters must be locked while working on the scaffold.

2. Check the weight of the scaffold and intended load when using casters.

3. To maintain a 4:1 safety factor, a scaffold 15 feet high with two (2) board decks is the largest scaffold that should be built with 8-inch casters. A scaffold 21 feet high with three (3) board decks is the largest scaffold that should be built with 12-inch casters. For heights greater than 21 feet, contact your engineer.

MAINTENANCE:

1. Casters should be periodically maintained. If they have grease fittings, they should be filled with a white lithium grease (ST-80 High-Performance Grease or its equivalent).

2. WD-40 can be used before application of grease or oil to loosen old grease and remove any rust buildup.

3. The caster bearings must be inspected for any wear or damage. Replace any casters that show signs of wear or damage.

4


Revised: 05/17/19

INSTANTLOCK 2 VERTICAL POST

PART # DESCRIPTION

EFFECTIVE LENGTH(INCHES)

OVERALL LENGTH W/ PIN(INCHES)

TUBE LENGTH (INCHES)

WEIGHT GALVANIZED

(LBS.)

IL2CP Vertical Coupling Pin 11.5 — — 1.8

IL2SC InstantLock 2 Starter Collar 13 18 18 6.8

IL2VP19 1'-7" InstantLock 2 Vertical 19.66 25.69 19.66 9

IL2VP39 3'-3" InstantLock 2 Vertical 39.35 41.43 39.35 15.5





MATERIAL SPECS:

1. All tubing is 1.90 diameter, 11-gauge (0.120 wall), high-strength, minimum 50,000 yield, and 75,000 tensile. Tube length is the length of tubing required to manufacture each vertical.

2. Rosette spacing is 19.685 inches center to center. 3. Verticals are compatible with standard 1.90 OD tube

and clamp, and pin and ring material. 4. When connecting verticals, a vertical pin with snap

buttons must be used to align the verticals.

Clamp bolts should have between 40 and 65 lbs. tension. Overtightening could damage the threads, bolt or item the clamp is attached to.

CAUTION: There is a pinch point located where two verticals are pinned together.

Use caution when passing verticals. Ensure the vertical pin is correctly fastened.

WARNING: Two- (2) rosette verticals should only be used as the top of a vertical column. Two- (2) rosette verticals cannot have a vertical pin inserted in the top and bottom. The snap buttons will not lock on both pins and may create a drop hazard.

7"

IL2VP118 IL2VP98 IL2VP78 IL2VP59 IL2VP39 IL2VP19

118"

98"

78"

59"

39"

19"

INSTANTLOCK 2 STARTER COLLAR

5


Revised: 05/17/19

INSTANTLOCK 2 VERTICAL POST LOADING

UNBRACED POST LENGTH (INCHES)MAXIMUM ALLOWABLE COMPRESSIVE LOAD WHEN RATED

FOR SCAFFOLD USE (LBS.)

78 4,700

59 5,500

39 6,800

Allowable loads include OSHA 4:1 safety factor.

When designing scaffolds with unique configurations or special loading conditions, consult with a professional engineer (P.E.).

COMPRESSIVE LOAD

COMPRESSIVE LOAD

UN

BRAC

ED P

OST

LEN

GTH

TIE-OFF LOCATION

PARAMETER

6'-6"

6


Revised: 05/17/19

INSTANTLOCK 2 HORIZONTAL BAR

PART # DESCRIPTION

VERTICALPOST SPACING

(INCHES)

OVERALL WIDTH

(INCHES)TUBE LENGTH

(INCHES)

WEIGHT GALVANIZED

(LBS.)

IL2PB24 2' Bearer 24 22 17.38 10.5

IL2PB36 36" Bearer 36 34 29.38 11.5

IL2PB42 3'-6" Bearer 42 40 35.38 12.5

IL2PB48 4' Bearer 48 46 41.38 13

IL2PB60 5' Bearer 60 58 53.38 15.5

IL2PB72 6' Bearer 72 70 65.38 18

IL2PB84 7' Bearer 84 82 77.38 20

HORIZONTAL LEDGER

IL2HL96 8' Ledger 96 94 89.38 21

IL2HL108 9' Ledger 108 106 101.38 22

IL2HL120 10' Ledger 120 118 113.38 25.5

MATERIAL SPECS:

1. Tube length is the length of tubing required to manufacture each horizontal.

2. Tubing for the 7-foot bearer through the 10-foot ledger are 1.90 diameter, 12-gauge (0.108 wall), high-strength tubing minimum 65,000 yield, 75,000 tensile.

3. Horizontals are compatible with standard 1.90 OD tube and clamp material.

InstantLock 2 horizontals are equipped with one cable assist lever (shown in red), which releases both ends of the horizontal, and two triggers which control only that end of the horizontal. The InstantLock 2 end connector design allows metal scaffold boards to be placed the full length of the horizontal. The horizontal is capped on the top to prevent debris from entering into the trigger locking mechanism.

CAUTION: There is a pinch point when closing the trigger.

7


Revised: 05/17/19

INSTANTLOCK 2 HORIZONTAL BAR

BUILD NOTES:

1. In order to gain full effectiveness of the cable assist feature, all triggers should be placed together at vertical joints.

2. The following methods will assist with builder training: • Builders must be trained on the function

differences between the cable assist lever, and trigger assemblies.a.) Cable assist lever opens both end connectors. b.) Triggers function independently of the cable

assist lever.

• When installing the horizontal, hold the cable assist lever end toward yourself and squeeze the lever. This will open both trigger gates.

• Connect the horizontal to both verticals releasing the cable assist lever.

• Tug/twist and visually inspect the horizontal to make sure both triggers have proper seating within the vertical rosettes.

• When inspecting a completed scaffold, ensure all triggers align vertically where a horizontal is connected at each joint.

3. InstantLock 2 horizontals are not approved for use when hanging scaffolds.

TRIGGER OPERATES ITS END ONLYCABLE ASSIST LEVER

OPERATES BOTH ENDS

CABLE

TRIGGER CABLE ASSIST LEVER

TRIGGER

HORIZONTAL SCAFFOLD BAR DESIGNED WITH CABLE AND SPRING-LOADED TRIGGER ASSEMBLY

8


Revised: 05/17/19

INSTANTLOCK 2 HORIZONTAL BAR LOADING

PART # DESCRIPTION


(INCHES)

ALLOWABLE CENTER LOAD

(LBS.)

ALLOWABLE UNIFORM LOAD

(LBS./FT.)

IL2PB24 24" Bearer 24 2,250 2,250

IL2PB36 36" Bearer 36 1,100 680

IL2PB42 3'-6" Bearer 42 1,000 571

IL2PB48 4' Bearer 48 900 450

IL2PB60 5' Bearer 60 625 250

IL2PB72 6' Bearer 72 530 177

IL2PB84 7' Bearer 84 410 117

Horizontal LedgerIL2HL96 8' Ledger 96 320 80IL2HL108 9' Ledger 108 275 61

IL2HL120 10' Ledger 120 250 50

BUILD NOTES:

1. Vertical leg may be the limiting load carrying member.

2. Center load is applied to the center four (4) inches of the bearer or ledger.

Post Spacing

Center Load4"

Uniform Load

9


Revised: 05/17/19

INSTANTLOCK 2 HORIZONTAL BAR MULTIPLE-BAY LOADING

BEARER

LEDGER LENGTH

IL2PB24 IL2PB36 IL2PB42 IL2PB48 IL2PB60 IL2PB72 IL2PB84 IL2HL96 IL2HL108 IL2HL120

LENGTH(INCHES) 24 36 42 48 60 72 84 96 108 120

IL2PB24 24 1125 750 643 563 450 375 321 281 250 225

IL2PB36 36 340 227 194 170 136 113 97 85 76 68

IL2PB42 42 286 190 163 143 114 95 82 71 63 57

IL2PB48 48 225 150 129 113 90 75 64 56 50 45

IL2PB60 60 125 83 71 63 50 42 36 31 28 25

IL2PB72 72 88 59 50 44 35 29 25 22 20 18

IL2PB84 84 59 39 33 29 23 20 17 15 13 12

IL2HL96 96 40 27 23 20 16 13 11 10 9 8

IL2HL108 108 31 20 17 15 12 10 9 8 7 6

IL2HL120 120 25 17 14 13 10 8 7 6 6 5

Chart shows the total allowable load per square foot (live load + dead).

All areas below 25 lbs./sq. ft. (in green) do not meet OSHA requirements for a light-duty scaffold. OSHA 1926.451 (a) 6 in conjunction with non-mandatory Appendix A, define uniform loads for scaffold types.

BUILD NOTE:

Deck planking or verticals may be the limiting load carrying member.

Continuous-Run Scaffold

Bearer ContributingLength (X) ft.

Bear

er

(X) f

t.

10


Revised: 05/17/19

BEARER

LEDGER LENGTH


LENGTH(INCHES) 24 36 42 48 60 72 84 96 108 120

IL2PB24 24 2250 1500 1286 1125 900 750 643 563 500 450

IL2PB36 36 680 453 388 340 272 227 194 170 151 136

IL2PB42 42 571 381 327 286 229 190 163 143 127 114

IL2PB48 48 450 300 257 225 180 150 129 113 100 90

IL2PB60 60 250 167 143 125 100 83 71 63 56 50

IL2PB72 72 177 118 101 88 71 59 50 44 39 35

IL2PB84 84 117 78 67 59 47 39 33 29 26 23

IL2HL96 96 80 53 46 40 32 27 23 20 18 16

IL2HL108 108 61 41 35 31 24 20 17 15 14 12

IL2HL120 120 50 33 29 25 20 17 14 13 11 10

BUILD NOTES:

1. Bearer supports the boards. 2. Deck planking or verticals may be the limiting load

carrying member.


INSTANTLOCK 2 HORIZONTAL BAR SINGLE-BAY LOADING

Chart shows the total allowable load per square foot (live load + dead load).

Alternating Bays

Bear

er (X

) ft.

Runner (X) ft.

Single Bay

Bearer (X) ft.

Bearer (X) ft.

Runner (X) ft.

Runner (X) ft.

Bear

er (X

) ft.

Bear

er (X

) ft.

Runn

er (X

) ft.

Runn

er (X

) ft.

11


Revised: 05/17/19

BRACING INSTANTLOCK 2 HORIZONTAL BARS

PART # DESCRIPTION


(INCHES)


(LBS.)


(LBS./FT.)

IL2PB60 5' Bearer 60 1,200 480

IL2PB72 6' Bearer 72 975 325

IL2PB84 7' Bearer 84 975 250

HORIZONTAL LEDGER

IL2HL96 8' Ledger 96 750 188

IL2HL108 9' Ledger 108 675 150

IL2HL120 10' Ledger 120 625 125

Bracing can be added to InstantLock 2 horizontal bars when greater strength is required.

Diagonal pin braces, short diagonal braces, or tube and clamp may be used to provide additional strength to the InstantLock 2 horizontal bar.

BUILD NOTES:

1. The angle of the bottom connection of the brace to the vertical must be 45 degrees or less.

2. The brace must be placed within 18 inches of either side of the center of the horizontal. Vertical leg may be the limiting load carrying member.

3. Horizontal bracing adds additional torque to the verticals, which must be considered when building heavy-duty or tall scaffolds.


CENTER LINE

45° OR LESS

36"

12


Revised: 05/17/19

INSTANTLOCK 2 HORIZONTAL BAR WITH ONE (1) BRACE

Standard board layout.

Chart shows the allowable load per square foot when horizontal is braced as defined on page 11—horizontal bracing.Chart shows the total allowable load per square foot (live load + dead load).


Bear

er

(X) f

t.


BEARER

LEDGER LENGTH


LENGTH(INCHES) 24 36 42 48 60 72 84 96 108 120

IL2PB60 60 240 160 137 120 96 80 69 60 53 48

IL2PB72 72 163 108 93 81 65 54 46 41 36 33

IL2PB84 84 125 83 71 63 50 42 36 31 28 25

IL2HL96 96 94 63 54 47 38 31 45 23 21 19

IL2HL108 108 75 50 43 38 30 25 21 19 17 15

IL2HL120 120 63 42 36 31 25 21 18 16 14 13


BUILD NOTES:

1. Bearer supports the boards and has one (1) diagonal brace.

2. Deck planking or verticals may be the limiting load carrying member.

13


Revised: 05/17/19

BUILD NOTES:



All areas below 25 lbs./sq. ft. do not meet OSHA requirements for a light-duty scaffold. OSHA 1926.451 (a) 6 in conjunction with non-mandatory Appendix A, define uniform loads for scaffold types.

INSTANTLOCK 2 HORIZONTAL BAR WITH ONE (1) BRACE

Single-bay scaffold or staggered board deck layout.

Bear

er (X

) ft.

Runner (X) ft.

Single Bay

Chart shows the allowable load per square foot when horizontal is braced as defined on page 11—horizontal bracing.Chart shows the total allowable load per square foot (live load + dead load).

BEARER

LEDGER LENGTH


LENGTH(INCHES) 24 36 42 48 60 72 84 96 108 120

IL2PB60 60 480 320 274 240 192 160 137 120 107 96

IL2PB72 72 325 217 186 163 130 108 93 81 72 65

IL2PB84 84 250 167 143 125 100 83 71 63 56 50

IL2HL96 96 188 125 107 107 94 63 54 47 42 38

IL2HL108 108 150 100 86 75 60 50 43 38 33 30

IL2HL120 120 125 83 71 63 50 42 36 31 28 25

Alternating Bays

Bearer (X) ft.

Bearer (X) ft.

Runner (X) ft.

Runner (X) ft.

Bear

er (X

) ft.

Bear

er (X

) ft.

Runn

er (X

) ft.

Runn

er (X

) ft.

14


Revised: 05/17/19

INSTANTLOCK 2 ADJUSTABLE BEARER

PART # DESCRIPTION

MINIMUMPOST

SPACING(INCHES)

MAXIMUM POST SPACING(INCHES)

WEIGHT GALVANIZED

(LBS.)

IL2TPB36 36" to 48" Adjustable Bearer 36 47 12





IL2THL96 96" to 108" Adjustable Ledger 96 107 32

Fixed Ledgers

Adjustable Ledger

Adjustable bearers are designed to provide deck support between two (2) self-supporting scaffold structures where traditionally only tube and clamp could be used.

Adjustable bearers may also be used to create odd-sized scaffolds (ex: 5 feet x 6 1/2 feet).

MATERIAL SPECS:

1. Outer tubing is 1.90 diameter, 11-gauge (0.120 wall), high-strength, minimum 65,000 yield, and 75,000 tensile.

2. Inner tubing is 1.625 diameter, 11-gauge (0.120 wall), high-strength, minimum 65,000 yield, and 75,000 tensile.

CAUTION: There is a pinch point when closing the trigger and where the parts telescope.

WARNING: Adjustable bearers provide limited longitudinal support.

Intermediate horizontal adapters may only be placed on adjustable bearers if designed by an engineer.

15


Revised: 05/17/19

INSTANTLOCK 2 ADJUSTABLE BEARER (CONT'D)

PART NUMBER DESCRIPTIONALLOWABLE CENTER

LOAD (LBS.)

ALLOWABLE UNIFORM LOADWHEN FULLY EXTENDED

(LBS./FT.)

36" to 48" Adjustable Bearer 812 406





96" to 108" Adjustable Ledger 562 125

PART # DESCRIPTIONALLOWABLE CENTER

LOAD (LBS.)

ALLOWABLE UNIFORM LOADWHEN FULLY EXTENDED

(LBS./FT.)

IL2TPB36 36" to 48" Adjustable Bearer 812 406





IL2THL96 96" to 108" Adjustable Ledger 562 125

Uniform Load

Center Load 4"

BUILD NOTES:



16


Revised: 05/17/19

Chart shows the total allowable load per square foot (live load + dead load).Chart shows worst case scenario— adjustable bearer fully extended.



Bear

er

(X) f

t.


BUILD NOTES:



BEARER

LEDGER LENGTH

IL2PB24 IL2PB42 IL2PB48 IL2PB60 IL2PB72 IL2PB84 IL2HL96 IL2HL108 IL2HL120

Length(inches) 24 42 48 60 72 84 96 108 120

IL2TPB36 47 203 116 102 81 68 58 51 45 41

IL2TPB48 59 125 71 63 50 42 36 31 28 25

IL2TPB60 71 125 71 63 50 42 36 31 28 25

IL2TPB72 83 98 56 49 39 33 28 25 22 20

IL2TPB84 95 77 44 39 31 26 22 19 17 15

IL2THL96 107 62 36 31 25 21 18 16 14 12


MULTIPLE-BAY LOADING

17


Revised: 05/17/19

Chart shows the total allowable load per square foot (live load + dead load).Chart shows worst case scenario—adjustable bearer fully extended.

Bear

er (X

) ft.

Runner (X) ft.

Single Bay


BUILD NOTES:



BEARER

LEDGER LENGTH

IL2PB24 IL2PB42 IL2PB48 IL2PB60 IL2PB72 IL2PB84 IL2HL96 IL2HL108 IL2HL120

Length(inches) 24 42 48 60 72 84 96 108 120

IL2TPB36 47 271 232 203 162 135 116 102 90 81

IL2TPB48 59 167 143 125 100 83 71 63 56 50

IL2TPB60 71 167 143 125 100 83 71 63 56 50

IL2TPB72 83 131 112 98 79 65 56 49 44 39

IL2TPB84 95 103 88 77 62 52 44 39 34 31

IL2THL96 107 83 71 62 50 42 36 31 28 25


SINGLE-BAY LOADING

Alternating Bays

Bearer (X) ft.

Bearer (X) ft.

Runner (X) ft.

Runner (X) ft.

Bear

er (X

) ft.

Bear

er (X

) ft.

Runn

er (X

) ft.

Runn

er (X

) ft.

18


Revised: 05/17/19

INSTANTLOCK 2 TRUSSES

PART # DESCRIPTIONLENGTH(INCHES)

DEPTH(INCHES)

DISTANCEA/B (FT.)

NUMBER OF STABILIZERS

WEIGHT GALVANIZED

(LBS.)A (FT.) B (FT.)

IL2TR4 4' Truss 46 9.5 — — — 27

IL2TR5 5' Truss 58 9.5 — — — 29

IL2TR6 6' Truss 70 9.5 3 — 1 31

IL2TR7 7' Truss 82 10.75 3.5 — 1 33

IL2TR8 8' Truss 96 13.375 4 — 1 45.5

IL2TR9 9' Truss 106 13.375 4.5 — 1 53

IL2TR10 10' Truss 118 13.375 5 — 1 54.5

IL2TR12 12' Truss 142 15 3 6 2 63.5

IL2TR14 14' Truss 166 15 3.5 7 2 82

IL2TR16 16' Truss 190 15 4 8 2 92

IL2TR18 18' Truss 214 15 5 8 2 110

Center Load 4" Min.

4' – 6' Truss

A A

Center Load 4" Min.

7' – 10' Truss

A A

Side Stabilizer Connector

MATERIAL SPECS:

All load-bearing tubes are 1.90 diameter, 11-gauge (0.120 wall), high-strength min. 65,000 yield, 75,000 tensile.

BUILD NOTES:

1. Trusses should be installed in pairs and have side stabilizers installed if side stabilizer connector is present. When the stabilizers cannot be installed, tube and clamp should be installed directly next to the stabilizer connector near the top chord.

2. A single truss can be installed if properly braced or tied back to an adjacent leg or structure.

CAUTION: There is a pinch point when operating the trigger.

12' – 18' TrussA A


B

Center Load 4" Min.

4' – 6' Truss

19


Revised: 05/17/19

INSTANTLOCK 2 TRUSSES (CONT'D)

Center Load 4" Min.

4' – 6' Truss

A A Center Load 4" Min.

7' – 10' Truss

A A


PART # DESCRIPTIONALLOWABLE CENTER LOAD

(LBS.)ALLOWABLE UNIFORM LOAD

(LBS./FT.)

IL2TR4 4' Truss 3,000 1,500

IL2TR5 5' Truss 3,000 1,200

IL2TR6 6' Truss 2,750 910ALLOWABLE UNIFORM LOAD

WITH SIDE STABILIZERS (LBS./FT.)

IL2TR7 7' Truss 3,000 857

IL2TR8 8' Truss 3,500 875

IL2TR9 9' Truss 3,500 775

IL2TR10 10' Truss 3,500 700

IL2TR12 12' Truss 3,500 575

IL2TR14 14' Truss 3,000 428

IL2TR16 16' Truss 2,000 250

IL2TR18 18' Truss 2,000 220

BUILD NOTES:


2. Center load is applied to the center four (4) inches of the truss.

12' – 18' TrussA A


B

Center Load 4" Min.

20


Revised: 05/17/19


WARNING: Additional bracing is required for areas in green. Please consult with your qualified person and/or engineer.



Bear

er

(X) f

t. All areas below 25 lbs./sq. ft. (in green) do not meet OSHA requirements for a light-duty scaffold. OSHA 1926.451 (a) 6 in conjunction with non-mandatory Appendix A, define uniform loads for scaffold types.

BUILD NOTE:


BEARER

LEDGER LENGTH


LENGTH(INCHES) 24 36 42 48 60 72 84 96 108 120

IL2TR4 48 600 400 343 300 240 200 171 150 133 120

IL2TR5 60 600 400 343 300 240 200 171 150 133 120

IL2TR6 72 455 303 260 228 182 152 130 114 101 91

IL2TR7 84 429 286 245 214 171 143 122 107 95 86

IL2TR8 96 438 292 250 219 175 146 125 109 97 88

IL2TR9 108 388 258 221 194 155 129 111 97 86 78

IL2TR10 120 350 233 200 175 140 117 100 88 78 70

IL2TR12 144 288 192 164 144 115 96 82 72 64 58

IL2TR14 168 214 143 122 107 86 71 61 54 48 43

IL2TR16 192 125 83 71 63 50 42 36 31 28 25

IL2TR18 216 110 73 63 55 44 37 31 28 24 22

INSTANTLOCK 2 TRUSSES (CONT'D)MULTIPLE-BAY LOADING

21


Revised: 05/17/19



BUILD NOTE:


Bear

er (X

) ft.

Runner (X) ft.

Single Bay

BEARER

LEDGER LENGTH


LENGTH(INCHES) 24 36 42 48 60 72 84 96 108 120

IL2TR4 48 1200 800 686 600 480 400 343 300 267 240

IL2TR5 60 1200 800 686 600 480 400 343 300 267 240

IL2TR6 72 910 607 520 455 364 303 260 228 202 182

IL2TR7 84 857 571 490 429 343 286 245 214 190 171

IL2TR8 96 875 583 500 438 350 292 250 219 194 175

IL2TR9 108 775 517 443 388 310 258 221 194 172 155

IL2TR10 120 700 467 400 350 280 233 200 175 156 140

IL2TR12 144 575 383 329 288 230 192 164 144 128 115

IL2TR14 168 428 285 245 214 171 143 122 107 95 86

IL2TR16 192 250 167 143 125 100 83 71 63 56 50

IL2TR18 216 220 147 126 110 88 73 63 55 49 44

INSTANTLOCK 2 TRUSSES (CONT'D)SINGLE-BAY LOADING

Alternating Bays

Bearer (X) ft.

Bearer (X) ft.

Runner (X) ft.

Runner (X) ft.Be

arer

(X) f

t.

Bear

er (X

) ft.

Runn

er (X

) ft.

Runn

er (X

) ft.

22


Revised: 05/17/19

PART # DESCRIPTION

WEIGHT GALVANIZED

(LBS.)


(FT.)


(LBS.)


{LBS./FT.}

RLLG14 Lattice Girder 14' 98 14 3,395 474





INSTANTLOCK 2 LATTICE GIRDERS

Lattice girders are static trusses used to span large distances, such as over roadways and other obstructions.


23


Revised: 05/17/19

VERTICAL DIAGONAL BRACE WEDGE HEAD DESIGN

PART # DESCRIPTION

TOTAL LENGTH OF BRACE (INCHES)

BAY WIDTH SPACING(INCHES)

HEIGHT LENGTH(INCHES)

WEIGHT GALVANIZED

(LBS.)

RLD36 3' Diagonal Brace 85.9 36 78 17.6

RLD42 3'-6" Bay 88.6 42 78 18








Compatible vertical diagonal bracing may be used with InstantLock 2 components.

BUILD NOTES:

1. Load capacities may vary depending on application and bracing being used.

2. Spacing between vertical rings on the vertical must be verified to ensure proper fit of the diagonals.

3. Per OSHA, bracing should be placed as close to the nodes as possible.

24


Revised: 05/17/19

DIAGONAL PIN BRACE

PART # DESCRIPTIONSINGLE FITS POSTSPACING (INCHES)

DOUBLE FITS POSTSPACING (INCHES)

LENGTH(INCHES)

WEIGHT GALVANIZED

(LBS.)

DPB Diagonal Pin Brace 24 - 84 96 - 168 108 24

SDPB Short Diagonal Pin Brace Horizontal Bracing 36 8

BEARER DESCRIPTION X COORDINATE Y COORDINATE

24" Bearer, 2-Plank Bearer 24 105.3

36" Bearer 36 101.82




6' Bearer 72 80.5

7' Bearer 84 67.88

8' Ledger 96 193.49

9' Ledger 108 187.06

10' Ledger 120 179.6

The diagonal pin brace is a multipurpose brace. It has standard swivel clamps on each end, so it can be fastened to any scaffold vertical or horizontal.

These braces are also drilled and fitted, so a standard vertical pin can be used to connect two or more braces together. This may be desirable when there is a need to brace longer structures up to 14 feet.

BUILD NOTE:

When more than one (1) brace is used, the brace should be tied, when possible, in the middle with #9 wire or equivalent to a horizontal, vertical or another diagonal. When braces are connected together, the middle clamps may or may not be used.

14'

TIE WIREY

X

25


Revised: 05/17/19

The short diagonal pin brace can be used to provide additional support to horizontal bearers or to extend the length of a diagonal pin brace for use on a 10-foot wide scaffold.

The diagonal pin brace can also be used as a vertical to pass through a congested area, such as a pipe rack or cable tray.

BUILD NOTE:

When used as a vertical, the diagonal pin brace must be supported by tube and clamp, braces, or tied, so there is never more than 69 inches of unsupported vertical.

MATERIAL SPECS:

1. All tubing is 1.90 diameter, 11-gauge (0.120 wall), high-strength, minimum 65,000 yield, and 75,000 tensile.

2. Diagonal pin braces are compatible with standard 1.90 OD tube and clamp material.


CAUTION: There is a pinch point at the clamp and where the parts pin together

DIAGONAL PIN BRACE (CONT'D)

UNBRACED POST LENGTH (INCHES)MAXIMUM ALLOWABLE COMPRESSIVE LOAD

WHEN RATED FOR SCAFFOLD USE (LBS.)

36 2,550

108 2,550

26


Revised: 05/17/19

Bracing and/or tying should be applied to any scaffold where the top of the scaffold has movement of more than six (6) inches in any direction. The bracing should be placed to run in opposite directions on opposing sides. It may be zigzagged or run in the same direction. (See normal bracing diagram pg. 27.)

Horizontal bracing that is attached diagonally from vertical to vertical should be placed every 19.5 feet max.

Single-bay scaffolds should be braced on a minimum of two (2) sides and when feasible on all four (4) sides, starting at the bottom and continuing to a minimum of 10 feet from the top of the scaffold.

All other bay configurations require bracing placed on one (1) bay for every 30 feet of scaffold (generally every 4th bay). At a minimum, bracing should be placed on the inside and outside row of the scaffolding verticals, starting at the bottom and continuing to a minimum of 10 feet from the top of the scaffold.

Scaffolds that contain side brackets or outriggers, where there is a possibility of tipping, must also be braced or tied with tube and clamp to plant approved structural steel components (i.e., I-beams, handrails, grating, etc.)

ADDITIONAL BRACING RECOMMENDATIONS FOR LIGHT-DUTY SCAFFOLD:

Bay widths of 42 inches and less, that are less than 20 feet tall, may not require bracing. The InstantLock 2 horizontal design acts as a truss, providing necessary bracing. Scaffolds above 20 feet tall should be braced using clamp braces or tube and clamp applied to the bottom of the scaffold, leaving an unbraced height of 20 feet or less. (Bracing should always be added if there is excessive movement of the scaffold structure.)

Scaffolds with a deck height less than 10 feet do not require bracing provided they are tied off with tube and clamp to plant approved structural steel components (i.e., I-beams, handrails, grating, etc.).

ADDITIONAL BRACING RECOMMENDATIONS FOR MEDIUM- AND HEAVY-DUTY SCAFFOLD:

Heavy-duty scaffolds should have as much bracing as required to meet the desired loading. Bracing and/or tying should be placed on all sides of the scaffold. Multi-bay scaffolds should have bracing on every other bay, front, middle and back rows. (See heavy-duty bracing diagram pg. 27.)

INSTANTLOCK 2 SYSTEM SCAFFOLD GENERAL GUIDELINES FOR BRACING

WARNING: Heavy-duty scaffolds require additional bracing. Please consult with your qualified person and/or engineer.

THE FOLLOWING BRACING RECOMMENDATIONS ARE FOR ALL NON-SEISMIC SCAFFOLDING BUILT USING INSTANTLOCK 2 SCAFFOLD COMPONENTS.

27


Revised: 05/17/19

GENERAL GUIDELINES FOR BRACING (CONT’D)

NORMAL BRACING (ZIGZAG OR UNIFORM)

HEAVY-DUTY BRACING

30°–60°

BUILD NOTES:

1. When attaching diagonal bracing, ensure it is within one (1) foot of the closest horizontal node points.

2. Angle is most effective between 30 and 60 degrees between brace and horizontal.

28


Revised: 05/17/19

PART # DESCRIPTION

EFFECTIVE WIDTH

(INCHES)NET WIDTH

(INCHES)

OVERALL WIDTH

(INCHES)

OVERALL HEIGHT

(INCHES)

WEIGHT GALVANIZED

(LBS.)

IL2SB24 2' Side Bracket 24 20.5 26 19.5 14.5

IL2SB36 3' Side Bracket 36 34.5 38 19.5 23.3

MATERIAL SPECS:

All tubing is 1.90 diameter, 11-gauge (0.120 wall), high-strength, minimum 65,000 yield, and 75,000 tensile.

2-FOOT SIDE BRACKET 3-FOOT SIDE BRACKET

INSTANTLOCK 2 SIDE BRACKETS

PART # DESCRIPTIONMAXIMUM UNIFORM LOAD (LBS./SQ. FT.)

MAXIMUM LOAD ON END(LBS.)

IL2SB24 2' Side Bracket 500 500

IL2SB36 3' Side Bracket 330 500

CAUTION: There is a pinch point when closing the trigger.

Check that the vertical pin is properly secured before handling.

29


Revised: 05/17/19

PART # DESCRIPTIONEFFECTIVE WIDTH

(INCHES)NET WIDTH

(INCHES)WEIGHT GALVANIZED

(LBS.)

RLSB11 11" Board Bracket 11 11 3.6

RLSB24 2-Board Bracket 24 19.70 12.5

RLSB34 3-Board Bracket 34 28.28 16.6

RLSB36 36" Board Bracket 36 32.08 15.2

WEDGE LOCK HEAD SIDE BRACKETS

PART # DESCRIPTIONMAXIMUM UNIFORM LOAD (LBS./SQ. FT.)

RLSB11 11" Board Bracket 250

RLSB24 2-Board Bracket 500

RLSB34 3-Board Bracket 500

RLSB36 36" Board Bracket 500

11" SIDE BRACKET

24" SIDE BRACKET


24" TO 36"

30


Revised: 05/17/19

INSTANTLOCK 2 INTERMEDIATE HORIZONTAL ADAPTER

Locking intermediate horizontal adapters and spigot clamps are used to extend legs on a suitable truss or bearer to bridge around objects. Legs extending further than 4-feet 11-inches require lateral support to the bearer by tube and clamp, horizontal, deck, or horizontal at the first connection of leg above bearer.

Locking intermediate horizontal adapters, used in pairs, create a bearer at the mid-span of a bay.

BUILD NOTES:

1. With a single bearer, the maximum vertical on a locking intermediate horizontal adapter is 4-feet 11-inches.

2. The locking intermediate horizontal adapter meets guardrail loading criteria when used with a lower horizontal, but it is NextGen's recommendation to add a tube and clamp or additional means to support the guardrail.

3. The maximum load is based on the weakest component. Ensure decking allowance is taken into account.

4. Spigot clamp is not to be used as a guardrail post base unless supported in two (2) directions or additional bracing is added.


CAUTION: Do not pass material to another employee with an intermediate horizontal adapter attached.

PART NUMBER DESCRIPTIONWEIGHT

(LBS.)MAXIMUM VERTICAL

LOAD (LBS.)

IL2IHAL Locking Intermediate Horizontal Adapter 18 The maximum load is based on the weakest

component. Ensure decking allowance is taken into account. RLSC Spigot Clamp* 8.9

IL2IHAL

SPIGOTCLAMP

*Third-party manufactured component. Data may vary.

31


Revised: 05/17/19

ILSWP

INSTANTLOCK 2 SHORT INTERMEDIATE HORIZONTAL ADAPTER

The short locking intermediate horizontal adapter is utilized to deck around a protrusion/opening that does not require a guardrail.

The short locking intermediate horizontal adapter with pin can be utilized to support a guardrail.

BUILD NOTES:

1. With a single bearer, the maximum vertical on a locking intermediate horizontal adapter or short locking intermediate horizontal adapter with pin is 4-feet 11-inches.

2. Maximum point load on a short locking intermediate horizontal guardrail post is 200 lbs. outward and vertically.

3. When a short locking intermediate horizontal adapter is supporting a board deck, the deck load must be limited to light-duty only.

4. Short locking intermediate horizontal adapters are used strictly for guardrailing around protrusions only and should not be used to add additional decking to increase the scaffold height.

5. The maximum load is based on the weakest component. Ensure decking allowance is taken into account.

CAUTION: Do not pass material to another employee with an intermediate horizontal adapter attached.

PART NUMBER DESCRIPTIONWEIGHT

(LBS.)MAXIMUM VERTICAL

LOAD (LBS.)

ILSNP Short Locking Intermediate Horizontal Adapter 4.5The maximum load is based on the weakest component. Ensure decking allowance is taken into account.

ILSWP Short Locking Intermediate Horizontal Adapter with Pin 7

ILSNP

ILSNP INSTALLATION

ILSWP INSTALLATION

32


Revised: 05/17/19

INSTANTLOCK 2 METAL BOARDS

PART # DESCRIPTIONWIDTH

(INCHES)WEIGHT

(LBS.)UNIFORM LOAD

(LBS./FT.)CENTER LOAD

(LBS.)

SP24 2' Plank 9 11.5 271 600

SP36 3' Plank 9 16 271 600

SP42 3.5' Plank 9 18 232 546

SP48 4' Plank 9 18.8 213 520

SP60 5' Plank 9 23.5 185 480

SP72 6' Plank 9 28.5 105 388

SP84 7' Plank 9 30.5 100 322

SP96 8' Plank 9 37.5 93 284

SP108 9' Plank 9 41.5 69 250

SP120 10' Plank 9 46.5 58 233

6SP24 6" x 2' Plank 6 10.5 271 600

6SP36 6" x 3' Plank 6 12.9 271 600

6SP42 6" x 3.5' Plank 6 14.5 232 546

6SP48 6" x 4' Plank 6 16.1 213 520

6SP60 6" x 5' Plank 6 19.4 185 480

6SP72 6" x 6' Plank 6 22.6 105 388

6SP84 6" x 7' Plank 6 25.9 100 322

6SP96 6" x 8' Plank 6 27.7 93 284

6SP108 6" x 9' Plank 6 32.4 69 250

6SP120 6" x 10' Plank 6 35.6 58 233

SIDE PROFILE LOCKING MECHANISM

BUILD NOTE:

Where a possibility of uplift could occur, all boards should be securely attached to the scaffold with #9 wire, tie wraps, toe boards, filler plates or other equivalent means.

33


Revised: 05/17/19

INSTANTLOCK 2 WOOD PLANKS

NextGen purchases only quality wood planks that meet OSHA requirements for lumber type and density. The following is the required inspection/storage procedure for boards:

1. The boards should be inspected before they are put into service for damage and wear. All planks must be inspected routinely for damage and wear, so that they can be replaced as quickly as necessary.

2. Identification of damage: Employees shall be trained to recognize the following types of wear/damage:

• Decay: Boards should be examined to determine if age/weathering/wear is excessive. Wood ages and reacts to usage and will begin to show checks, splits and notches. These will vary in degree, depending on the loads a plank has carried, the weather to which it has been exposed, the length of time it has been in use, etc. Planks with splits—cracks that go completely through the wood for more than a few inches—should not remain in service, as they may no longer maintain the necessary load-bearing capacity. Planks with checks—cracks that are on the surface only and do not go completely through the wood— should be watched, as the checks may develop into splits over time.

• Damage: Does the board contain any notches, cuts or other visual damage that would render it unsafe to use? Notched plank can lead to problems since a portion of the plank is missing, thereby weakening the plank at that particular area. If a scaffold plank has been used as a mudsill, it should not be returned to service on a platform. Moisture from standing water, as well as point-loading from the scaffold legs may have weakened it, making it unable to bear the weight that will be placed on it.

• Chemical/heat damage: Has the board been exposed to excessive chemicals/heat (soaked with oil, scorch marks)? Scaffold planks that have visible chemical or scorch marks must be removed from service.

• Surface covering: Is the surface free from items that may cause a slip (oil/tar/etc.)? OSHA [1926.451(b)(9)] says that scaffold planks that have accumulated layers of mortar, grout, paint, plaster, etc., are not permitted to remain in service since it is impossible to determine their condition. Dangerous splits may be hidden underneath those coatings.

• Shrinkage: Has the board size decreased past its useful size?

• Deflection: The flex or “give” of a plank can indicate its condition. OSHA calls for deflection criteria of L/60 (the length of span in inches divided by 60) to get the maximum deflection limit at center span in inches. An example would be a seven-foot (84-inch) span between scaffold frame supports: 84/60 = 1.40 inches. Therefore, you’d never want to allow a plank to deflect more than 1 3/8 inches at the middle of that length span, regardless of type of plank being used. Only sample testing should be performed since test loading can damage the board.

34


Revised: 05/17/19

INSTANTLOCK 2 WOOD PLANKS (CONT'D)

Allowable loads when rated for scaffold use include OSHA 4:1 safety factor.

PART # DESCRIPTION

MAXIMUM LOADING USING FULL THICKNESS UNDRESSED LUMBER

(LBS./SQ. FT.) WEIGHT (LBS.)MAXIMUM SCAFFOLD

SPAN (FT.)

WP-4 4' Wood Plank 75 18 2



WP-10 10' Wood Plank 25 45 8

WP-12 12' Wood Plank 25 54 10

MAINTENANCE NOTES:

1. When not in use, all wood planks should be stored above ground on dunnage to keep moisture from entering the bottom of the boards.

2. Additionally, all boards should have some sort of wood slats or spacers between layers to allow for air circulation through the boards.

3. Most important, a tarp or something as simple as a sheet of plywood should be placed over the top of the boards to prevent moisture from dropping down through the stack. Ideally, indoor storage is best.

BUILD NOTE:

Where a possibility of uplift could occur, all boards should be securely attached to the scaffold with #9 wire, tie wraps, toe boards, filler plates or other equivalent means.

6"–12"

35


Revised: 05/17/19

INSTANTLOCK 2 FILLER PLATES

PART # DESCRIPTION WEIGHT (LBS.)

FP24 Filler Plate 24" 3.1










Filler plates are designed to fit all types of scaffolding to cover gaps between wood or metal boards.

Filler plates come in various lengths and contain holes that allow the filler plate to be tied or nailed in place.

Filler plates are designed with wider slots on one end to allow it to be installed without bending.

MATERIAL SPECS:

All filler plates are made from 10-gauge galvanized steel.

BUILD NOTE:

When tying filler plates, a single strand of #9 wire at each end is required.

36


Revised: 05/17/19

Duckbill planks (overlapping steel planks) can be used to fill gaps in decks created by obstructions. They rest on the two (2) adjacent steel planks or steel planks and bearer, thereby reducing the need for wood planking.

Duckbill planks are attached to the planks they are resting on with #9 wire or self-tapping screws through the holes provided in the plank.

BUILD NOTE:

1. The loading of the duckbill plank and adjacent planks must be taken into consideration when designing the scaffold

2. There must be a minimum overlap of 5 inches at each end of the plank on the bearing surface to prevent slippage.

INSTANTLOCK 2 DUCKBILL PLANK

PART NUMBER DESCRIPTIONWIDTH

(INCHES)OVERALL LENGTH

(INCHES)WEIGHT

(LBS.)UNIFORM LOAD

(LBS./FT.)CENTER

LOAD (LBS.)

DBP24 2' Duckbill Plank 9 42 12.5 250 500

DBP36 3' Duckbill Plank 9 54 17 228 500

DBP42 42" Duckbill Plank 9 60 19 211 500




DPB84 7' Duckbill Plank 9 102 31.5 100 322




6DBP24 6" x 2' Duckbill Plank 6 42 10.5 271 600


6DBP42 6" x 42" Duckbill Plank 6 60 14.5 232 546








37


Revised: 05/17/19

INSTANTLOCK 2 FOUNDATION EQUIPMENT

PART # DESCRIPTION WEIGHT (LBS.)MAXIMUM SUPPORTED

LOADS (LBS.)

BSIB06 6' Foundation I-Beam 78 5,500

Bchair Static Ladder Chair 16.5 5,500

BSAVC Adjustable Vee Chair 19.5 5,500

BSF1 12" Founding Ladder 13.4 5,500




BSFS Founding Ladder Starter 7.5 5,500

BSSB10 10' Saddle Brace 17.5 5,500


Founding ladder vee chairs are attached to the founding ladders and provide a level surface for the leveling jacks to rest.

Founding ladders rest on the slope of the boiler tubes and the foundation beams.

BUILD NOTES:

1. All OSHA and plant regulations governing safety shall be followed, whichever is stricter.

2. The area supporting the foundation beams must be able to handle the required imposed loads.

3. Attached equipment (i.e. verticals, etc.) may be the load limiting factor.

FOUNDINGLADDER

VEE CHAIR

FOUNDING LADDERSTARTER

BEAM

38


Revised: 05/17/19

INSTANTLOCK 2 LADDER

PART # DESCRIPTION

OVERALL LENGTH(INCHES)

MAX. TOTAL VERTICALLOAD ON

LADDER (LBS.)

MAX. LOAD ONONE (1) LADDER

RUNG (LBS.)

WEIGHT GALVANIZED

(LBS.)

LA10 10' ladder 118 1,000 500 42

LA9 9' ladder 106.5 1,000 500 36

LA8 8' ladder 95 1,000 500 34

LA7 7' ladder 83.5 1,000 500 32.1

LA5 5' ladder 60.5 1,500 500 22.2

LA4 4' ladder 49 1,500 500 18.3

LA3 3' ladder 37.5 2,000 500 14.3

LA2 2' ladder 26 2,000 500 8

LA1 1' ladder 14.5 2,000 500 4.1

BUILD NOTES:

1. When installing ladders, the female end should always be placed at the bottom to prevent debris from collecting in the end of the ladder.

2. Ladders are not designed to support loads, such as walkways, pipe supports, pipe hangers, lifting rigs, etc.

3. Ladders should only be used for access to scaffolds. 4. The ladder brackets may limit the load carrying

ability of the ladder.

FEMALEEND

39


Revised: 05/17/19

INSTANTLOCK 2 LADDER BRACKET

PART # DESCRIPTION

OVERALL WIDTH

(INCHES)

MAX TOTAL VERTICAL LOAD ON BRACKET

(LBS.) WEIGHT (LBS.)

LB3 Clamp Bracket 12 600 12.3

Clamp brackets may be installed on the horizontal bars or vertical posts.

BUILD NOTE:

1. Use more brackets when necessary to carry greater loads. The ladder may be the load limiting member.

2. The first ladder of each ladder section must have a ladder bracket at the bottom to start ladder runs. Every ladder will have a ladder bracket at the top of each ladder rung (including starter ladder).


BRACKET TO BE INSTALLED WITHIN BOTTOM 3 RUNGS.

BRACKET TO BE INSTALLED WITHIN TOP 3 RUNGS.

40


Revised: 05/17/19

INSTANTLOCK 2 ALUMINUM LADDER

PART # DESCRIPTION


MAX. TOTAL VERTICALLOAD ON LADDER


RUNG

WEIGHT GALVANIZED

(LBS.)

ALA10 10' Aluminum Ladder 120 1,000 500 24



8-ALA10 8" wide 10' Aluminum Ladder 120 1,000 500 22

8-ALA5 8" wide 5' Aluminum Ladder 60 1,500 500 11

8-ALA3 8" wide 3' Aluminum Ladder 36 2,000 500 6.5

AEP Expansion Pin 7.5 NA NA 2.5

BUILD NOTES:

1. To prevent rotation of vertical, one of the following methods must be used when installing base ladder:• Ladder must touch the ground.• Diagonal pin braces must be installed on all

sides of the scaffold. • If tube and clamp or extendable braces are used

in lieu of pin bracing, a short diagonal brace must be installed from the ledger to the vertical in both directions. See illustration above.

2. Bracing must always be attached to the leg, not the starter collar.

3. The expansion pin should always be securely tightened.

Expansion pin bolts should have between 40 and 65 lbs. tension. Overtightening could damage the threads, bolt or ladders the expansion pin is attached to.

EXPANSION PIN

SHORT DIAGONAL BRACES

41


Revised: 05/17/19

INSTANTLOCK 2 SNOW LADDER

PART # DESCRIPTION


MAX. TOTAL VERTICALLOAD ON

LADDER (LBS.)


RUNG (LBS.)

WEIGHT GALVANIZED

(LBS.)

SLA5 5' Snow Ladder 60.5 1,500 500 19.5

SLA3 3' Snow Ladder 37.5 2,000 500 10

SLB1 Snow Ladder Bracket — — — 3

Snow ladders provide a greater non-slip tread for use in snow, ice or other slippery conditions.

Rugged, extra-grip rungs help prevent slips.

Snow ladders are not compatible with regular ladder brackets and must use the clamp and pin style snow ladder bracket. The base of snow ladders must be placed on mudsill, grade or the deck.

BUILD NOTE:

1. Snow ladders are not designed to support loads, such as walkways, pipe supports, pipe hangers, lifting rigs, etc. Ladders should only be used for access to scaffolds.

2. When installing ladders, the female end should always be placed at the bottom to prevent debris from collecting in the end of the ladder.


42


Revised: 05/17/19

INSTANTLOCK 2 LADDER CAGE

PART NUMBER DESCRIPTION WEIGHT (LBS.)

LC Ladder Cage Hoop 10

SLC Snow Ladder Cage Hoop 12

LC3/4-L Ladder Cage 3/4 Hoop Left 9

LC3/4-R Ladder Cage 3/4 Hoop Right 9

SLC3/4-L Snow Ladder Cage 3/4 Hoop Left 11

SLC3/4-R Snow Ladder Cage 3/4 Hoop Right 11

LCB4 Ladder Cage Brace 4' 3.5

LCB2 Ladder Cage Brace 2' 1.8

3/4 Hoop Left

3/4 Hoop Right

Ladder Cage Hoop

Ladder cage accessories allow ladder cages to be added to most scaffold ladders.

BUILD NOTES:

1. The ladder cage should always be removed starting from the bottom towards the top to prevent the swinging of brace components while being dismantled.

2. Ladder cage 3/4 hoops are used to create an opening in the ladder cage to exit to different deck elevations.

3. Tube and clamp is used to provide a handrail at the opening and can be adjusted to fit any scaffold design.

4. Any combination of horizontals/tube and clamp can be used for the handrail.

5. The installer should ensure the cage extends down the ladder to a point not less than seven (7) feet and no more than eight (8) feet above the base of the ladder. It should also extend a minimum of 42 inches above the top of the landing, unless other acceptable protection is provided.

43


Revised: 05/17/19

INSTANTLOCK 2 RIGHT-ANGLE BRACE

PART NUMBER DESCRIPTION WEIGHT (LBS.)

RAB Right-Angle Brace 3.5

A right-angle brace is used to ensure the scaffold stays square or to provide additional corner support for the end connectors.

Right-angle braces can be used to support a stand-off (90-degree) ladder access.

Right-angle braces can be used for ladder additions or bracing on scaffolds with casters.

BUILD NOTE:

Braces must have bolts.

44


Revised: 05/17/19

Stair systems are designed to provide safe access for scaffolds. Stairs can be designed using side brackets or multi-bay scaffolds. Stairs are designed for 30-, 36- and 42-inch widths. All boards are self-locking, no wiring is required.

BUILD NOTES:

1. Stairs are rated for light duty, 25 lbs./sq. ft.. 2. Handrails are comprised of diagonal braces.

WARNING: Improper use of stairs could cause serious injury. Always use handrails and step in the center of the treads. Walk down the stair tower, do not run, do not skip any steps. Non-slip adhesive tape may be applied to the edge of the metal boards for additional safety. Users should maintain 3-point contact with the stair. Only metal boards used on stair risers should be used.

INSTANTLOCK 2 STAIR SYSTEM

PART NUMBER DESCRIPTIONWEIGHT GALVANIZED

(LBS.)

SSS7 7' Stair Stringer 44.1

SST30 30" Stair Tread 11.7



DSB Handrails (Pin Removed or Snap Button Unlocked) 24.8

45


Revised: 05/17/19

Safety gates are designed to provide safe access for scaffolds and can be installed on any 36-inch wide scaffold bay. For greater versatility, the safety gate is equipped with clamps and designed to fit all types of scaffolding.

BUILD NOTES:

1. To install a safety gate on a larger-sized scaffold bay (5-feet to 10-feet), a 36-inch side bracket, heavy-duty intermediate horizontal adapter, gate post or gate adapter can be installed with shorter bars to support the gate. The gate must only be attached to the existing vertical post and not to the end of the side bracket, heavy-duty intermediate horizontal adapter, gate post or gate adapter.

2. To properly install the safety gate, first place the gate on the vertical and lightly secure the clamps. Then, rotate the gate around the vertical toward the outside of the scaffold until the spring has enough tension that the gate remains closed. Finally, tighten the clamps to hold the gate in place. When properly placed, the strike plate should touch 50% or more of the vertical post. During periodic scaffold inspections, the gate may require that the clamps be loosened and the gate rotated to re-tighten the spring.

3. InstantLock 2 material or tube and clamp should be used to close off areas greater than 36 inches.

4. Gates can be used on bays smaller than 36 inches, as long as they open and latch properly.

5. The safety gate may be flipped to allow the gate to swing in either direction.

MAINTENANCE NOTES:

1. Gates should be periodically maintained. If they have grease certs, they should be filled with a white lithium grease (ST-80 High-Performance Grease or its equivalent). Gates without grease certs should be lubed with a 10-weight oil or dry graphite.

2. WD-40 can be used before application of grease or oil to loosen old grease and remove any rust buildup. The gate must be cycled (swung in both directions) as many times as necessary to allow the oil/grease to work in and allow the gate to swing freely.


SG2 Safety Gate with Clamps 21

INSTANTLOCK 2 SAFETY GATE


46


Revised: 05/17/19


IL2HDGP InstantLock 2 Heavy-Duty Gate Post 25

The InstantLock 2 heavy-duty gate post is used to create a custom-width swing gate opening for access.

BUILD NOTES:

1. The gate post is not an approved tie-off point.2. All swing gate requirements remain the same when

using a gate post. (See page 45.)3. Gate post meets 200 lbs. load rating for handrail

systems. 4. Confirm bottom wedge is driven before attaching

handrail system.

INSTANTLOCK 2 HEAVY-DUTY GATE POST

47


Revised: 05/17/19


IL2GA InstantLock 2 Gate Adapter 21.4

The InstantLock 2 gate adapter is used to create a custom-width swing gate opening for access.

BUILD NOTES:

1. The gate adapter is not an approved tie-off point.2. All swing gate requirements remain the same when

using a gate adapter. (See page 45.)3. The gate adapter meets 200 lbs. load rating for

handrail systems. 4. Confirm bottom wedge is driven before attaching

handrail system.

INSTANTLOCK 2 GATE ADAPTER


48


Revised: 05/17/19

ALUMINUM TOE BOARD

PART # DESCRIPTION WIDTH (IN.) WEIGHT (LBS.)

ATB-24 2' Aluminum Toe Board 24 6


ATB-42 42" Aluminum Toe Board 42 9



ATB-72 6' Aluminum Toe Board 72 13.5





CAUTION: Holes in the toe board are for nailing to wood planks. Use caution when nailing to prevent damage to the toe board.

The aluminum toe board with locking clips, is designed to fit all types of scaffold material. The toe board locks the scaffold boards down—eliminating the need to wire boards to the horizontals. Installation times are greatly reduced with this equipment.

BUILD NOTE:

Ensure the push button is exposed when engaging the toe board.

49


Revised: 05/17/19

ROSETTE CLAMP

The rosette clamp can be installed between existing rosettes to create a connection point for horizontals or trusses.




RC Rosette Clamp 2.5

50


Revised: 05/17/19

RING LOCK SUSPENSION CONNECTOR

The ring lock suspension connector is used to connect two (2) verticals together when scaffold is suspended. This component should only be used in pairs.

BUILD NOTES: 1. Ring lock suspension connectors are to be used in

pairs when suspending scaffolds.2. Required on every scaffold vertical at each

connection point.


LOAD (LBS.)

RLSC Ring Lock Suspension Connector 8.8 5,000


51


Revised: 05/17/19


RLTW Twin Wedge Head 1.6

TWIN WEDGE HEAD


InstantLock 2 can be used for shoring applications, however it must be designed by an engineer.

For two or four legs, the twin wedge head should be placed in three- (3) foot increments.

BUILD NOTES: 1. Standard safety factor of 4:1 for typical scaffold and

2.5:1 for shoring.2. Shoring scaffold must be tied every 13 feet minimum.

TWIN WEDGE HEADIN SHORING APPLICATION

AS SEEN FROM ABOVE

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Revised: 05/17/19

TWIN WEDGE HEAD (CONT'D)

TWIN WEDGE HEADIN SHORING APPLICATION

(4 LEGS)

UNBRACED POST LENGTH (INCHES)

MAXIMUM ALLOWABLE COMPRESSIVE LOAD WHEN RATED FOR SCAFFOLD USE

(LBS.)

MAXIMUM ALLOWABLE COMPRESSIVE LOAD WHEN RATED FOR SHORING USE

(LBS.)

DATA PENDING ANALYSIS OF LOADING DATA.

BUILD NOTE:

Diagonal bracing is comprised of standard 1.9-inch tube and 3.5- x 1.9-inch swivel clamps.

ENGINEERING:

1. Allowable loads when rated for scaffold use, include OSHA (4:1) factor.

2. Allowable loads when rated for shoring use, include OSHA (2.5:1) factor.

3. All shoring applications shall have a drawing provided by a NextGen Engineer and require a P.E. stamp.

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Revised: 05/17/19

INSTANTLOCK 2 USED WITH TUBE AND CLAMP

The tube and clamp adapter is designed to provide a safe, strong method to transition from InstantLock 2 to tube and clamp.

MATERIAL SPECS:

InstantLock 2 material is 100% compatible with most types of tube and clamp.

BUILD NOTES:

When tube and clamp scaffolding is used to continue a vertical above the InstantLock 2 system, the load ratings and restrictions of the tube and clamp manufacturer must be used.


TCA Tube and Clamp Adapter 3.5

TU-20 20' Tube 30

TU-16 16' Tube 27

TU-13 13' Tube 22

TU-10 10' Tube 21

TU-8 8' Tube 18

TU-6 6' Tube 14

TU-4 4' Tube 11

SWC Swivel Clamp 3

RAC Right-Angle Clamp 4

SBC Swivel Beam Clamp 4

RBC Rigid Beam Clamp 4

MBP-1 Male Base Plate 5

MALE TUBE AND CLAMP CONNECTOR

HOLES TO FIT INSTANTLOCK 2 VERTICAL PIN

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Revised: 05/17/19

INSTANTLOCK 2 USED WITH TUBE AND CLAMP

BUILD NOTES:

1. Tube and clamp material has been manufactured by many different vendors. There is no easy way to identify the manufacturer or the quality of material used in its construction. Always assume that the material is of lesser quality and use the most conservative designs when building with this material.

2. Tube and clamp material must be assembled in strict accordance with all current Federal and State guidelines. (See OSHA 1926.452(b) “Tube and coupler scaffolds.”)

MATERIAL NOTES:

1. The strength of the scaffold is greatly affected by the torque on the bolted connections.

2. Tube lengths of 16 and 20 feet, without proper support, may not meet minimum requirements for scaffold loads.

3. Most scaffold tube material is manufactured with 1.90 diameter tubing.

4. Rigid beam clamps and swivel beam clamps must be inspected for damage/cracking at the weld and the top bend of the clamp. Beam clamps have been know to fracture at the top bend area.


Check bend forcracking orbending.

Check bolt for damage.

Check rivets or weld for signs of wear.

55


Revised: 05/17/19

INSTANTLOCK 2 USED WITH TUBE AND CLAMPWHEN TYING TO AN EXISTING STRUCTURE

YOKE TIE FOR BEAM 1. Secure the beam from all sides using tube and

clamp as shown.2. Use backup clamps to prevent slippage of the

tubing.

BUILD NOTES:

1. Swivel beam clamps and rigid beam clamps should be used only for scaffold bracing or as shown.

2. To support a scaffold structure, use tube and clamp or heavy-duty support beam clamps designed for such use.

For other configurations contact the NextGen Engineering Department.

CAUTION: When installing swivel and rigid beam clamps for hanging scaffold, please consult pages 56-58 of this manual for typical configurations and capacities, as well as proper installation of beam clamps.

TYING SCAFFOLD TO COLUMN OR BEAM

YOKE TIE FOR BEAM

TYING SCAFFOLD TO COLUMN OR BEAM1. Clamps are to always be used in pairs.2. When possible, use the beam clamps on the top

flange of the beam. 3. Beam clamps are attached to top of the I-beam

where the load is not on the clamp bolt.4. When the top of the beam cannot be reached

because of an obstruction, tube and clamp cut to length or tubing designed to fit between two beams can be used for support.

56


Revised: 05/17/19

BUILD NOTES:

1. Install right-angle clamp directly below any rosette of the InstantLock 2 vertical.

2. Connect tube and two (2) beam clamps to the top flange of the approved beam.

3. Connect the vertical to the tube clamped to the bottom of beam.

MATERIAL NOTE:

All tube used to be 1.9" OD, 1.6" ID standard tube and coupler material.


SCAFFOLD SUPPORTED FROM TOP OF BEAM FLANGE WITH INSTANTLOCK 2 VERTICAL

1

2

3

HANGING/SUSPENDED SCAFFOLD

57


Revised: 05/17/19

HANGING/SUSPENDED SCAFFOLD (CONT'D)

BUILD NOTES:


2. Connect tube and two (2) beam clamps to the bottom flange of the approved beam.


MATERIAL NOTE:



1

2

3

SCAFFOLD SUPPORTED FROM BOTTOM OF BEAM FLANGE WITH INSTANTLOCK 2 VERTICAL

58


Revised: 05/17/19

1

2

3 & 4

HANGING/SUSPENDED SCAFFOLD (CONT'D)

SCAFFOLD SUPPORTED FROM BOTTOM OF BEAM FLANGE WITH INSTANTLOCK 2 VERTICAL WITH TUBE & CLAMP AT 45-DEGREE MINIMUM TO LOADED VERTICAL

BUILD NOTES:


2. Connect tube and two (2) beam clamps to the bottom flange of the approved beam.


4. Install 45-degree support tube and clamp bracing.

MATERIAL NOTE:



59


Revised: 05/17/19

CANTILEVERED SCAFFOLD

CANTILEVERED SCAFFOLD USING INSTANTLOCK 2 TRUSSES

1. Start from a rigid frame scaffold set on a suitable base (not hanging). This starter scaffold is to be of adequate dimensions and properly anchored to an approved structure prior to installing the cantilevered scaffold. The starter scaffold is to be utilized as a tie-off location.

2. Remove the two (2) hitch pins from the horizontal hinge assembly on one (1) InstantLock 2 truss allowing the hinges to rotate freely. Work in groups of two (2) with Builder 1 on the working platform and Builder 2 on the platform below. Working together, stage the InstantLock 2 truss, so the truss swings horizontally with the wedges on top. The first truss will be installed level with the working platform, at the Builder 1 's feet.

3. Builder 1 (at the top of the truss) installs the top wedge by driving it into place, while Builder 2 checks the truss for level and plumb.

4. Once level, the bottom wedge of the truss can be driven into place by Builder 2. It is important that the truss is kept plumb using a level. A misaligned truss can rotate along the vertical axis, possibly creating an unsafe structure.

5. If necessary, the bottom truss is now installed below following steps 2 thru 5.

6. A vertical is installed at the open end of the truss while folded up against the starter scaffold.

7. The leveled truss is now fully secured to verticals on each end. Then, Builder 1 can rotate the truss 90 degrees, locking it into position using the supplied hitch pins.

8. Steps 2 thru 8 are now repeated for the second set of trusses.

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Revised: 05/17/19

COMPLETED CANTILEVER

TOE BOARDS AND ACCESS ARE NOT SHOWN FOR CLARITY

CANTILEVERED SCAFFOLD (CONT'D)

9. The planking is installed by sliding each plank out until fully decked. (The builder is tied off to the starter scaffold. Never tie off to the cantilever at this stage.)

10. Complete the cantilever by installing handrails followed by toe boards.

BUILD NOTES:

1. Swinging trusses can be used for a knee-out up to a maximum of 7-feet in length, so long as one of these requirements is implemented:• 45-degree tie back in tension or compression

to an approved supporting leg is used.• Double-truss configuration is used.

2. If swinging trusses are used in a cantilever bridge scenario, the builder must remain tied to an approved adjacent structure until the cantilever components are static on both ends.

3. Knee-outs over seven (7) feet require an engineer's involvement.

WARNING: InstantLock 2 horizontals should not be used for cantilever

applications. However, if the application is required, a qualified person must be contacted and the builder must have the proper training.

61


Revised: 05/17/19

ADJUSTABLE TUBE AND CLAMP ADAPTER


LOAD AT 12” (LBS.)

ATCA Adjustable Tube and Clamp Adapter 3.5 5,000

The adjustable tube and clamp adapter allows the elevation of a board deck to be changed, so that the top portion of a scaffold can be aligned with a scaffold built on a separate structure.

The adjustable tube and clamp adapter enables the vertical rosettes of one scaffold to be aligned with another scaffold built at a different elevation.

The adjustable tube and clamp adapter may be placed on top of an existing InstantLock 2 scaffold or tube and clamp scaffold.

BUILD NOTES:

1. There must be a wrap of horizontals (either InstantLock 2 or tube and clamp) attached to the verticals above and below the adjustable tube and clamp adapter.

2. There must always be a minimum of six (6) inches of thread inside the upper and lower vertical.

3. Only one (1) adjustable tube and clamp adapter may be used in any run of verticals.

4. Before use, inspect the adjustable tube and clamp adapter assembly to ensure there are no cracks in the wing nuts and verify that the three (3) tack welds are visibly in place.

5. The maximum spacing between the nuts is 12 inches.

MAX SPACING 12 INCHES

62


Revised: 05/17/19

INSTANTLOCK 2 AS A FALL PROTECTION ANCHORAGE POINT

In order to provide the safest work environment for all personnel, NextGen recommends that the scaffold not be used as a fall protection anchorage point when other locations or methods of fall protection anchorage are available. In the event that there is nothing else suitable for a fall protection anchorage point, InstantLock 2 may be used, providing the following prerequisite guidelines are followed.

1. The anchorage point may be made on a vertical/rosette above the last horizontal connection with a minimum of two (2) horizontals and within 6 feet of those connections, and as shown on the sketch on pg. 64.

2. The anchorage point may be made to a horizontal bar provided that both end connectors are securely locked in place.

a) InstantLock 2 trusses (page 18) can be used as an anchor point when all stabilizers are installed and both ends are secured.

b) Check with truss manufacturer for allowable loading of pin/wedge driven trusses.

c) Two- (2) through eight- (8) foot horizontals of any type may be used without modification for an anchorage point, as long as they are properly installed and in proper working condition.

d) Nine- (9) and ten- (10) foot horizontals with any end connector may be used if modified to include a tube and clamp support that ties a minimum of two (2) horizontals together at the center.

3. Only one individual can tie off to any anchorage point anywhere on a single vertical or horizontal. No one may tie off to any of the other horizontals that are tied together as part of the anchorage point.

4. The anchorage point must be as high as possible above the employees’ work area.

5. When a horizontal is used as a tie-off point, each vertical the horizontal is attached to must be secured by a minimum of one (1) other horizontal or equivalent.

6. The anchorage point must never be made to a vertical that does not extend to the ground or supporting structure. Never tie off to a gate, gate post or intermediate horizontal adapter.

7. All scaffolds that are built on any structure other than the ground shall be properly secured to the structure and be evaluated by a competent person prior to being used for a tie-off point.

8. All scaffold anchorage points must be evaluated by a competent person prior to being used.

9. If swinging trusses are used in a cantilever bridge scenario, the builder must remain tied to an approved adjacent structure until the cantilever components are static on both ends.

10. When the scaffold contains casters:

a) The casters shall be locked.

b) Outriggers, such as a properly designed tube and clamp outrigger that extends a minimum of 20 inches from the base of the scaffold, must be installed to prevent rolling and tipping of the scaffold.

c) The scaffold should also, when possible, be tied to an existing stable structure to prevent sliding or tipping.

11. When possible, scaffolds that are used for a tie-off anchorage point shall be secured to a permanent structure, tied, guy-wired, or provided with outriggers. If a scaffold is to be free standing, the scaffold must meet the following conditions:

a.) The scaffold is to have a minimum base of five- (5) feet long x five- (5) feet wide (excluding outriggers if used) and have a 3:1 height to base ratio.

b.) The scaffold is to have vertical diagonal bracing installed on all four (4) sides of a single bay scaffold from the base to the underside of the deck.

c.) When attaching to the vertical post of a free-standing scaffold, the point of connection shall have two (2) horizontal members attached at 90 degrees to each other, as close to the tie-off point as possible.

63


Revised: 05/17/19

UNACCEPTABLE TIE-OFF LOCATION

ACCEPTABLE TIE-OFF LOCATION





INSTANTLOCK 2 AS A FALL PROTECTION ANCHORAGE POINT (CONT’D)

64


Revised: 05/17/19

INSTANTLOCK 2 AS A FALL PROTECTION ANCHORAGE POINT (CONT’D)

d.) When attaching to a horizontal member, the conditions listed on Note 3 shall be adhered to at all times.

e.) Should a smaller base, free-standing scaffold be erected, the scaffold must be designed by an engineer prior to being erected.

f.) When available, the scaffold should be tied to an approved structure by either tube and clamp as close to the top deck as possible. This tie is to be made to the vertical members only and not attached to any horizontal members.

g.) This is in addition to tying required by Federal, State or local regulations.

h.) Anytime a free-standing scaffold is to be used for a tie-off anchorage point, it must be noted on the scaffold tag. NextGen may give different guidelines depending on the specific needs of the customer and the type of scaffold maintenance program and safe regulated work areas.

OSHA NOTE:

“Rescue considerations.” As required by 1926.502(d)(20), when personal fall arrest systems are used, the employer must ensure employees can be promptly rescued or can rescue themselves should a fall occur. The availability of rescue personnel, ladders or other rescue equipment should be evaluated. In some situations, equipment which allows employees to rescue themselves after the fall has been arrested may be desirable, such as devices which have descent control built in.

OSHA NOTE:

“Inspection considerations.” As required by 1926.502(d)(21), personal fall arrest systems must be regularly inspected. Any component with any significant defect, such as cuts, tears, abrasions, mold, or undue stretching, alterations or additions which might affect its efficiency, damage due to deterioration, contact with fire, acid, or other corrosives, distorted hooks or faulty hook springs, tongues unfitted to the shoulder of

buckles, loose or damaged mountings, non-functioning parts, or wearing of internal deterioration in the ropes must be withdrawn from service immediately, and shall be tagged or marked unusable and destroyed.

ENGINEERING NOTE:

Any material that is subjected to a load from a fall shall be replaced, even if there is no visible damage to the scaffold material. This includes verticals which may have been bent from the stresses from the fall. If it is not possible to immediately replace the material because of structural considerations, the material must be braced with tube and clamp or equivalent means and inspected by an engineer to ensure it is safe for continued use. In most cases, verification by a professional engineer (P.E.) may be required and is strongly recommended. The material must be replaced as soon as possible and the affected equipment tagged and removed from service.

6 FE

ET

MA

X

TIE-OFF LOCATION

PARAMETER

VERTICAL JOINT HAS TO BE BELOW THE TOP WRAP IN ORDER TO BE USED AS AN ANCHORAGE POINT.

65


Revised: 05/17/19

DAVIT ARM

PART NUMBER DESCRIPTION GALVANIZED WEIGHT (LBS.)

RLDAVIT Davit Arm Tie-off Bracket 22.46


The davit arm is used with a retractable lifeline, or lifeline, rope grab and standard lanyard.

Davit arm can also be used for lifting.

BUILD NOTES:

1. The davit arm is to have its top connection at the same elevation as the top full wrap of the scaffold.

2. A maximum of one (1) person can be tied off to the davit arm at one time.

3. Consult an engineer prior to using the davit arm for lifting. Additional tying and bracing may be required.

4. Only hand-operated systems shall be used (chainfall, come-along, rope and pulley).

5. No electric or mechanical lifting devices shall be used.

66


Revised: 05/17/19

INSTANTLOCK 2 TRUSS USED AS A LIFTING RIG

PART NUMBER DESCRIPTION

MAXIMUM ALLOWABLE LOAD (LBS.)

DESIGN A AND B DESIGN C

IL2TR4 4' Truss 3,000 6,000

IL2TR5 5' Truss 3,000 6,000

IL2TR6 6' Truss 2,750 5,500

IL2TR7 7' Truss 3,000 6,000

IL2TR8 8' Truss 3,500 7,000

IL2TR9 9' Truss 3,500 7,000

IL2TR10 10' Truss 3,500 7,000

IL2TR12 12' Truss 3,500 7,000

IL2TR14 14' Truss 3,000 6,000

IL2TR16 16' Truss 2,000 4,000

IL2TR18 18' Truss 2,000 4,000

I-Beam

Truss

A B C

Design C

Truss Truss

For design A and B, the nylon strap must be placed to prevent sideways twisting of the truss.

Shown left is an acceptable method of securing a beam to the top of the truss when using design C. Other methods are possible as long as the beam is secured from sliding off the truss.

1. The I-beam must be a minimum of four (4) inches at the base.

2. The listed loads are for the load attached to the center of the I-beam.

3. The I-beam may be the limiting load carrying member.

BUILD NOTES:

1. All loads are calculated using InstantLock 2 verticals to support the trusses. When using different configurations, the item the truss is attached to may be the load-limiting component.

2. Trusses should not be used as lifting rigs when connected to side brackets, verticals supported by side brackets, intermediate horizontal adapters or verticals supported by intermediate horizontal adapters.

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Revised: 05/17/19

BUILD NOTES:

1. All OSHA and plant safety regulations governing rigging and material handling must be followed.

2. All loose material must be removed or secured before lifting.

3. Spreader beams must be used, so that the lifting load on all vertical posts is applied in an upward direction.

4. The scaffold must be properly braced to prevent deformation during movement.

5. Scaffold weight loads must be calculated to prevent the overloading of any scaffold or lifting component.

6. All scaffold components (deck boards, etc.) must be secured to the scaffold.


CAUTION: Wire cable cannot be used for strapping. A strap must be a minimum of four (4) inches wide.

GUIDELINES FOR LIFTING RIGS

It is required to have a minimum of a four- (4) inch wide strap to prevent a small load area from bending the tube material on the truss. When a four- (4) inch strap is not available, the following can be used provided the new loading requirements are met:

1. The four- (4) inch wide value is defined for the maximum load applied to a truss.

2. Two 2-inch straps placed side by side can be used instead of a single four- (4) inch strap.• 2,000 lbs. for 16- and 18-foot truss• 2,750 lbs. for six- (6) foot truss• 3,000 lbs. for five- (5), seven- (7) and 14-foot

truss• 3,500 lbs. for eight- (8) through 12-foot truss

3. A single two- (2) inch strap can be used if the load is reduced to:• 800 lbs. for 16- and 18-foot truss• 1,100 lbs. for six- (6) foot truss• 1,200 lbs. for five- (5), seven- (7) and 14-foot


4. A three- (3) inch strap or two (2) 1.5-inch straps side by side can be used if the load is reduced to:• 1,000 lbs. for 16- and 18-foot truss• 1,375 lbs. for six- (6) foot truss• 1,500 lbs. for five- (5), seven- (7) and 14-foot


NYLON STRAP

LOAD

PULLEY OR MANUALLY

OPERATED HOIST

68


Revised: 05/17/19

LIFTING AND MOVING RACKED MATERIAL

The following general guidelines are provided for lifting and rigging InstantLock 2 material. These are general guidelines. Users should follow all Federal, State and local rigging guidelines. (See: OSHA – 1926.251, Rigging equipment for material handling, OSHA – 1926.753, Hoisting and rigging, OSHA – 1926 Subpart N, Cranes, Derricks, Hoists, Elevators, and Conveyors, other OSHA and ASME standards as applicable.)

InstantLock 2 scaffold racks may be used to hold material while lifting, provided the following guidelines are followed:

1. All material must be evenly balanced in the rack.

2. All material must be secured from sliding. (Two (2) ratchet straps, two (2) wraps of banding, or other approved method of securing the material shall be used.)

3. All material must be secured to the rack. (This can be accomplished by the same strapping/banding required above.)

4. Standard rigging procedures should be used to prevent movement of the straps while lifting the load. (Use of a spreader bar when possible is preferred.)

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Revised: 05/17/19

INSTANTLOCK 2 EQUIPMENT CARTS

PART # DESCRIPTIONWIDTH

(INCHES)HEIGHT

(INCHES)LENGTH(INCHES)

LOAD CAPACITY

(LBS.) WEIGHT (LBS.)

S-Cart Scaffold Cart 45.25 38.5 72 3,340 300

TS-Cart Towable Scaffold Buggy 52 48 132 2,000 480

BUILD NOTES:

1. Scaffold cart is only to be lifted by a forklift at pockets provided and all material strapped into place prior to lifting.

2. Only the towable scaffold buggy is meant to be towed by a motorized vehicle. Scaffold cart is to be pushed by man power.

3. Cart wheels are to be locked while loading and unloading to prevent movement.

4. The stabilizer at the back of the scaffold cart and buggy is to be used whenever the cart is stationary.

SCAFFOLD CART

TOWABLE SCAFFOLD BUGGY

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Revised: 05/17/19

SCAFFOLD SKID PAN

Maximum allowable loads shown includes the weight of the skid pan plus the pan’s contents.

PART # BOTTOM LENGTH (FT.) FULL LENGTH (FT.)EMPTY

WEIGHT (LBS.)MAX. LOADED WEIGHT

(LBS.)

SKID-8 6 8 900 3,000

SKID-10 8 10 1,050 3,000

Skid pans are used to move scaffold material from ground level closer to the location the material is required. This may be a higher elevation or across obstructions, such as fences, roads, streams, etc.

The following guidelines must be followed, regardless of the type of skid pan used:1. All skid pans, cables, shackles and associated

lifting equipment must be thoroughly inspected by the designated person when first delivered to the jobsite. The inspection must meet the requirements as defined in ASME B30.20-1-3.a) A visual inspection must be performed by a

qualified person making records of the apparent external condition to provide the basis for a continuing evaluation.

b) The inspection must be documented, dated and signed by the person performing the inspection.

2. For all equipment, inspect:a) Structurals for deformation, cracks or excessive

wear.b) Loose or missing guards, fasteners, covers, stops

or name plates.c) All functional operating mechanisms for

mis-adjustments interfering with operation.d) Deformation—Any bending or twisting

exceeding 10 degrees (or as recommended by the manufacturer) from the normal plane.

e) Throat opening—Any distortion causing an increase in the throat opening exceeding 15% (or as recommended by the manufacturer).

f) Wear—Any wear exceeding 10% (or as recommended by the manufacturer) of the original section dimensions.

3. Frequent visual examinations shall be performed weekly (or more frequently if recommended by the designated person) while the equipment is in service. No records required.

4. A documented thorough inspection shall be performed any time there is reason to believe part of the lifting equipment may have been damaged during use.

5. A skid pan shall not be used if it does not contain a label plate that lists the manufacturer, a serial number and the rated load.

6. When not in use, the skid pan and all lifting components shall be stored to protect the life of the equipment.

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Revised: 05/17/19

SCAFFOLD SQUARE STORAGE RACK

PART NUMBER DESCRIPTION WEIGHT (LBS.)DIMENSIONS (INCHES)

LENGTH X WIDTH X HEIGHTMAX.

CAPACITY (LBS.)

SSR Square Steel Rack 134 44.25 x 44.25 x 32.25 5,000


Square steel racks are designed to hold InstantLock 2 verticals, diagonals and other irregularly-shaped components.

When shipping, the square racks require two (2) pieces of banding to be placed around the base of the rack and the items being carried.

Square steel racks are designed so special casters can be placed on the bottom to allow the racks to be easily moved without a forklift. Always inspect rack feet for damage before installing casters or loading the rack.

STORAGE:

1. Square steel racks may be stacked for storage. The strength of the storage surface will determine how many racks can be stacked.

2. On grass, dirt or other unpacked surfaces, racks should be placed singly.

3. On prepared surfaces and asphalt, racks can be placed two (2) or three (3) high.

4. On three (3) or more inches of concrete, racks may be stacked three (3) or four (4) units high.

CAUTION: Always inspect the surface of the area where racks are stored for any cracking or sinking and inspect the racks for tilting or leaning.

WARNING: Racks should not be stacked more than four (4) units high.

BUILD NOTE:

Do not overload the casters when stacking a rack on top of a rack that contains casters.

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SCAFFOLD METAL BOARD STORAGE RACK

Steel board racks are designed to hold InstantLock 2 metal boards and other irregularly-shaped components.

Steel board racks will hold 62 metal boards four (4) feet or longer and 124 metal boards 32 inches or shorter.When shipping, the metal board racks require two (2) pieces of banding to be placed around the base of the rack and the items being carried.

Steel board racks are designed so special casters can be placed on the bottom to allow the racks to be easily moved without a forklift. Always inspect rack feet for damage before installing casters or loading the rack.

STORAGE:

1. Steel board racks may be stacked for storage. The strength of the storage surface will determine how many racks can be stacked.






BUILD NOTE:

Do not overload the casters when stacking a rack on top of a rack that contains casters.



CAPACITY (LBS.)

SBR Steel Board Rack 160 59.75 x 47 x 36 5,000

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Horizontal racks are designed for easy storage and inventory of InstantLock 2 horizontals. Each rack holds 96 horizontals and uses four (4) horizontals for support, for a total of 100 horizontals. To perform a quick inventory, simply count the full racks.

When shipping, the horizontal racks require one (1) piece of banding to be placed around the 96 center horizontals.

Horizontal racks are designed so casters can be placed on the bottom to allow the racks to be easily moved without a forklift.

STORAGE:

1. Steel board racks may be stacked for storage. The strength of the storage surface will determine how many racks can be stacked.






INSTANTLOCK 2 HORIZONTAL STORAGE RACK


WIDTH X HEIGHTMAX.

CAPACITY (LBS.)

IL2HR1 Horizontal Rack 79 44.5 x 38.5 3,000

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INSTANTLOCK 2 HORIZONTAL STORAGE RACK SUPPORT FOOT

Caution should be used when assembling or disassembling horizontal racks. The racks are heavy and have rough edges that can cause injury.

Care must be taken to make sure a loose rack will not fall. It should be safely supported on the ground or held by another worker during assembly and disassembly.

Always ensure the bottom horizontal is securely latched before beginning disassembly. The opposite horizontal rack can fall when the bottom horizontal is released if the horizontal is not securely latched on the other rack. Therefore, always disassemble racks from the outside.

The rack can still fall over if the ground is not level. The rack must be checked for stability before letting it stand on its own. Care must be taken to only assemble or disassemble racks on level ground.

WARNING: Beware of sharp edges.

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SCAFFOLD STORAGE BASKET



CAPACITY (LBS.)

FWB Folding Wire Basket 240 48 x 40 x 42 2,000

Folding wire baskets are designed to hold casters, ladder brackets, clamps and other small components only. Items should never be stacked above the rim in wire baskets.

When shipping, wire baskets may require a plywood lid to prevent items from bouncing out.

STORAGE:

Wire baskets may be stacked for storage.

WARNING: Wire baskets should never be stacked more than two (2) units high.

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OSHA COMPLIANCE OF INSTANTLOCK 2 SYSTEM SCAFFOLD

When InstantLock 2 System Scaffold material is assembled according to the loading and assembly requirements in the InstantLock 2 System Scaffold Standard Component Technical Manual the completed scaffold will meet OSHA regulations.

It is important to understand that OSHA does not regulate how scaffold material is manufactured. The manufacture of scaffold material is covered by ANSI and ASTM specifications. OSHA 1926.450-453 governs the construction of scaffolds using different types of scaffold material. The only restrictions that OSHA places on scaffold material are a 4:1 safety factor and loading values for decks, handrails and ladders.

This section is an explanation of how InstantLock 2 System Scaffold material meets the OSHA 1926.450-453 documents.

Ultimate Load The load values listed in this technical manual reflect all InstantLock 2 scaffold components have been tested to a minimum safety factor of 4:1.

1.A.) OSHA Standard requires a 4:1 safety factor for scaffold material that does not contain suspension rope.

1926.451 (a)(1)Except as provided in paragraphs (a)(2), (a)(3), (a)(4), (a)(5) and (g) of this section, each scaffold and scaffold component shall be capable of supporting, without failure, its own weight and at least four (4) times the maximum intended load applied or transmitted to it.Section (a)(2) refers to counterweights, section (a)(3) and (a)(4), suspension rope, section (a)(5)

scaffold hoist and (g) handrails.

InstantLock 2 scaffold material is tested to a better than 4:1 safety factor. ISO 9001-2000 test documentation is available upon request.

2.A.) The OSHA standard for handrails is 200 lbs.

1926.451(g)(1)(iv)Each employee on a self-contained adjustable scaffold shall be protected by a guardrail system (with minimum 200 lbs. top-rail capacity) when the platform is supported by the frame structure, and by both a personal fall arrest system and a guardrail system (with minimum 200 lbs. top-rail capacity) when the platform is supported by ropes.

All InstantLock 2 scaffold handrails exceed this value.

3.A.) OSHA provides for three (3 deck-loading values 25-lbs./sq. ft., 50-lbs./sq. ft. and 75-lbs./sq. ft..

Index to Appendix A for Subpart L1. (c) Fabricated planks and platforms may be used

in lieu of solid-sawn wood planks. Maximum spans for such units shall be as recommended by the manufacturer based on the maximum intended load being calculated as follows:

RATED LOAD CAPACITY INTENDED LOAD

Light-Duty 25 lbs. per square foot applied uniformly over the entire span area.

Medium-Duty 50 lbs. per square foot applied uniformly over the entire span area.

Heavy-Duty 75 lbs. per square foot applied uniformly over the entire span area.

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OSHA COMPLIANCE OF INSTANTLOCK 2 SYSTEM SCAFFOLD (CONT’D)

NOTE: Platform units used to make scaffold platforms intended for light-duty use shall be capable of supporting at least 25 lbs. per square foot applied uniformly over the entire unit-span area, or a 250 lbs. point load placed on the unit at the center of the span, whichever load produces the greater shear force.

4.A) The required load on stairs and ladders as defined by OSHA is two (2) loads of 250 lbs.

1926.451(e)(1)

When scaffold platforms are more than 2 feet (0.6 m) above or below a point of access, portable ladders, hook-on ladders, attachable ladders, stair towers (scaffold stairways/towers), stairway-type ladders (such as ladder stands), ramps, walkways, integral prefabricated scaffold access, or direct access from another scaffold, structure, personnel hoist, or similar surface shall be used. Crossbraces shall not be used as a means of access.

All InstantLock 2 scaffold equipment can be used to construct scaffolds that are 100% compliant with OSHA regulations.

When InstantLock 2 material is assembled and maintained using the requirements in the InstantLock 2 System Scaffold Standard Component Technical Manual, the completed scaffold will meet the OSHA regulations.

The following sections from the OSHA 1926.450-453 documents must be followed by the end-user to ensure all scaffolds are correctly constructed and all scaffold components correctly installed and maintained.

1926.454(b) The employer shall have each employee who is involved in erecting, disassembling, moving, operating, repairing, maintaining, or inspecting a scaffold trained by a competent person to recognize any hazards associated with the work in question. The training shall include the following topics, as applicable:

(b)(1) The nature of scaffold hazards;

(b)(2) The correct procedures for erecting, disassembling, moving, operating, repairing, inspecting, and maintaining the type of scaffold in question;

(b)(3) The design criteria, maximum intended load-carrying capacity and intended use of the scaffold;

(b)(4) Any other pertinent requirements of this subpart.

1926.451(f)(3) Scaffolds and scaffold components shall be inspected for visible defects by a competent person before each work shift, and after any occurrence which could affect a scaffold’s structural integrity.

(f)(4) Any part of a scaffold damaged or weakened such that its strength is less than that required by paragraph (a) of this section shall be immediately repaired or replaced, braced to meet those provisions, or removed from service until repaired.

1926.451(d)(10) Ropes shall be inspected for defects by a competent person prior to each work-shift. and after every occurrence which could affect a rope’s integrity. Ropes shall be replaced if any of the following conditions exist:

(d)(10)(i) Any physical damage which impairs the function and strength of the rope;

(d)(10)(ii) Kinks that might impair the tracking or wrapping of rope around the drum(s) or sheave(s);

(d)(10)(iii) Six (6) randomly distributed broken wires in one (1) rope lay or three (3) broken wires in one strand in one (1) rope lay;

(d)(10)(iv) Abrasion, corrosion, scrubbing, flattening or peening causing loss of more than one-third (1/3) of the original diameter of the outside wires;

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(d)(10)(v) Heat damage caused by a torch or any damage caused by contact with electrical wires;

(d)(10)(vi) Evidence that the secondary brake has been activated during an over-speed condition and has engaged the suspension rope.

1926.451(d)(12) When wire rope clips are used on suspension scaffolds: (d)(12)(i) There shall be a minimum of three (3) wire rope clips installed, with the clips a minimum of (six) 6 rope diameters apart;

(d)(12)(ii) Clips shall be installed according to the manufacturer’s recommendations;

(d)(12)(iii) Clips shall be re-tightened to the manufacturer’s recommendations after the initial loading;

(d)(12)(iv) Clips shall be inspected and re-tightened to the manufacturer’s recommendations at the start of each work-shift. thereafter;

(d)(12)(v) U-bolt clips shall not be used at the point of suspension for any scaffold hoist;

(d)(12)(vi) When U-bolt clips are used, the U-bolt shall be placed over the dead end of the rope, and the saddle shall be placed over the live end of the rope.

OSHA COMPLIANCE OF INSTANTLOCK 2 SYSTEM SCAFFOLD (CONT’D)

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INSTANTLOCK 2 BUILDING TIPS

The purpose of this section is to share valuable information on lessons learned and scaffold erection practices to make work activities safer, easier and more efficient for the end-user.

1. Always keep the most up-to-date copy of the InstantLock 2 System Scaffold Standard Component Technical Manual nearby. Visit the NextGen website, where it can be downloaded as needed. www.nextgenscaffold.com/resources

2. When constructing, modifying or removing InstantLock 2 scaffold material, it is very important that craft personnel handling the components in the field always wear the proper PPE (hard hat, gloves, safety glasses and safety shoes). Cut and impact resistant gloves are especially important to prevent accidental hand injuries that could be caused by the trigger mechanism on many InstantLock 2 components, which are a potential pinch point.

3. Two- (2) rosette verticals should never be used or pinned in the middle of other verticals. Two- (2) rosette verticals cannot have a vertical pin inserted in the top and bottom. The snap buttons will not lock on both pins and may create a drop hazard.

4. When building towers out of InstantLock 2 material, utilize the exact same building techniques you have always used with tube and clamp and other systems for bracing and board deck wrap requirements.

5. Take time during your initial jobsite walk down to gather the information and measurements required to make a detailed and accurate InstantLock 2 cut list for pulling material.

6. Do not try to memorize all of the different load ratings of InstantLock 2 work decks. Always refer back to the InstantLock 2 System Scaffold Standard Component Technical Manual to get the exact load ratings.

7. Do not attempt to build towers with InstantLock 2 scaffold material in a tight/restricted location where it has already been proven difficult using tube and clamp. It will be end up taking longer than tube and clamp.

8. Always start tower erection with adjustable screw jacks. You must assume the grade is not level. Always start at the highest point with a lowered jack.

9. Always do a visual inspection of the horizontal bars as the scaffold is being constructed to make sure the triggers are properly locked in place and that they are in the up position.

10. Light tapping of the horizontal bars on top of the end connector is allowed to get the trigger assembly properly locked into the rosettes/node points on the vertical leg.

11. Random field testing of InstantLock 2 scaffold components by unqualified personnel is not allowed. Any concerns, issues or questions with supplemental testing should always be referred to the manufacturing facility in Walker, LA to the attention of Lance Smith at (443) 293-6352.

12. Use a level to get the tower plumb/level at the very beginning of the build, on the very first base wrap, to prevent difficulty with bar placement all the way up.

13. Vertical rosette connections (node point, moment connections) are on 19.685-inch centers with a 7-inch spacing of each rosette connector's lower rosette the entire length of the vertical leg assembly.

14. Always have two (2) hands on components at any time, especially when setting a vertical leg on an existing vertical leg.

15. When setting a vertical leg on top of an existing leg, one hand shall support the upper leg, while the other hand depresses the spring clip. Then, slowly lower the top vertical leg down. Slightly twist the vertical until the spring clip locks into place. Do not drop the upper vertical leg onto the lower vertical pin.

16. To remove vertical legs that are connected, depress the spring clip, twist the upper vertical leg approximately 20 degrees, and with both hands lift to remove from lower vertical leg coupling pin.

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INSTANTLOCK 2 BUILDING TIPS (CONT’D)

17. All InstantLock 2 horizontal bars are two (2) inches shorter than the actual size, allowing for center-to-center measurement between vertical leg assemblies.

18. Two- (2) through seven- (7) foot InstantLock 2 horizontal bars are all load-bearing ledgers. All other InstantLock 2 horizontal bars are NON-load-bearing runners only.

19. You can board-deck out to eight- (8), nine- (9) and 10-foot runners, as long as you install one (1) diagonal brace back to the leg within 18 inches from the center of the runner.

20. Always install telescoping diagonal bracing after the first horizontal wrap, but before the second board deck wrap is put into place.

21. When passing (i.e., manual chain line) any type of telescoping brace (adjustable handrail or diagonal brace) ensure components are secured together by clip prior to upward or downward movement. This applies to adjustable toe boards, as well.

22. Diagonal braces connect four- (4) rosette pairs vertically (6 feet-6 inches), installed so that a horizontal is located at both the top and bottom diagonal end.

23. Do not exceed a maximum of a four- (4) rosette pair (6 feet-6 inches) spacing between horizontal board deck wraps from the top of lower horizontal bar wrap to the top of the next horizontal bar wrap.

24. When installing mid-rail and top handrail, use the following spacing from the board deck: one (1) rosette pair for mid-rail and an additional rosette pair for handrail. This method does not require a tape measure.

25. Standard handrail corner posts are always comprised of a minimum of a four- (4) rosette vertical leg.

26. When adding a leg in the middle of a horizontal bearer using and intermediate horizontal adapter, or on top of a side bracket or cantilever that does not go all the way to the ground, do not exceed 25 lbs./sq. ft., For loads greater than 25 lbs./sq. ft. you must consult an engineer.

27. When using truss assembly lifting rigs, always ensure you use a nylon strap that is at least four (4) inches wide or greater.

28. To properly install safety gates,, always connect these InstantLock 2 components to the vertical leg that goes all the way to the ground for stability.

29. When installing vertical access ladders, always remember the ears on the ladder bracket point up and are installed on the ladder first, then attached to the vertical post. Additionally, always install the vertical ladder with the male end of the ladder pointed up and the female end pointed down.

30. The approved tie-off area for fall protection is above the top handrail, where two (2) horizontal bars connect to a vertical leg. Refer to this manual on how to use horizontal bars, which are approved for tie-off purposes.

31. When building hanging InstantLock 2 scaffold, ensure you install a safety clamp onto the vertical leg directly above the InstantLock 2 horizontal bar that will be holding the weight of the leg going down.

32. Always use handrails and step in the center of treads. Walk down the stair tower, do not run, do not skip any steps.

33. Clamp bolts should have between 40 and 65 lbs. tension. Overtightening could damage the threads, bolt or item the clamp is attached to.

34. Never use rigid beam clamps or swivel beam clamps to hang or support a scaffold with the bolts. These types of clamps should only be used for bracing a scaffold or with the flat portion supporting the load.

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35. Be very careful not to overload trucks when shipping scaffold material. The maximum weight loaded should be capped at the maximum load the driver can legally carry. The user should validate the estimated weight by entering the quantity of scaffold components into a spreadsheet designed specifically to calculate and cross-check the total estimated weight. (A weight sheet can be made from our current List Price Sheet.)

36. When racking InstantLock 2 scaffold material, make sure to always use the proper racks and baskets. Do not make your own temporary racks out of miscellaneous scaffold parts that could come apart when loaded, unloaded or during transit, which could result in possible injury to personnel or property.

37. Casters are easy to overload when building a rolling scaffold. Scaffolds should be limited to two (2) work decks, 15 feet high when using eight- (8) inch casters and three (3) work decks, 21 feet high when using 12-inch casters.

38. Always inspect horizontal bars prior to installation to ensure the trigger, spring and cable are installed properly and functioning correctly. If you find an end connector with a broken trigger or cable, or weak spring, do not use that component. Pull it out of service and tag it for repair. Additionally, when installing ledgers or bearers, do not let go of the bar until you verify that it is properly locked into place and that the trigger is resting in the up position.

39. If you have questions regarding the contents of this manual; any ideas or suggestions on a new scaffold component design that would help make your job safer, quicker, easier; or any issues, concerns or problems regarding any InstantLock 2 scaffold components, please call Lance Smith, Engineering Design at (443) 293-6352.

INSTANTLOCK 2 BUILDING TIPS (CONT’D)

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CODE OF SAFE PRACTICES FOR INSTANTLOCK 2 SYSTEM SCAFFOLD

NextGen Scaffold recognizes that the scaffold industry is considered “inherently dangerous.” It is the intent of this section of the technical manual to provide pertinent guidelines for the proper, safe use, and maintenance of scaffold components and structures.

These guidelines are generalities and do not intend to cover every specific situation or component, they do not purport to be all-inclusive nor supplant other regulatory and precautionary measures for the safe use of scaffold in usual or unusual conditions. The primary codes or regulations are those promulgated by OSHA. They are Federal laws intended to provide a safe workplace by providing minimum reference guidelines upon which related activities should be carried out. It shall be the responsibility of all users/builders to avail himself and to comply with all applicable codes, regulations, standard and common sense practices designed to purport safety in the erection, use and dismantling of scaffold.

General Guidelines Prior to Use of Scaffolding:

1. Jobsite conditions within the boundaries of a refinery, chemical plant, manufacturing plant, pulp and paper mill, power plant or construction site may vary, and each presents unique circumstances. Efficient and proper planning of each job must be done by a competent, qualified person: OSHA 1926.451 (a) (3) No scaffold shall be erected, moved, dismantled or altered except under the supervision of competent persons.

2. The jobsite should be inspected and supervision be familiarized with proper access, proximity of power or process lines, obstructions, ground conditions, openings or pits, strength of supporting structure(s), interference with other workers, overhead protection, wind/weather protection and environmental hazards. These conditions must be evaluated and adequately provided for. Also, consider the protection of people who will be passing or working beneath or around scaffold structures.

3. The work to be done and the number of persons involved must be determined to properly calculate

the loading. The total loads and the supporting ground or structure must be considered when designing a scaffold structure—leg spacing, adequate sills, horizontal bracing, etc.

4. Stationary scaffolds over 125 feet in height and rolling towers over 60 feet in height must be designed by a professional engineer.

5. All equipment must be inspected to ensure it is in good condition. Damaged or deteriorated equipment should not be used and must be removed from service.

6. Scaffolds must be designed and used in accordance with the manufacturer’s specifications and recommendations. Do not intermix different brands of scaffold, unless authorized by the manufacturer, or plan to use materials in any manner other than what the manufacturer intended their design to accommodate.

7. When planning the job, remember to use common sense, sound judgment and qualified reasoning for the following:a.) Provide adequate foundations.b.) Provide proper access. c.) Provide proper bracing. d.) Provide proper handrails and toe boards.e.) Provide adequate decking materials.f.) Design scaffold structure on components to

adequately compensate for all intended loads. Use only qualified personnel who are in good shape—emotionally and physically.

8. Read, understand and comply with all Federal (OSHA), State, and local codes and regulations pertaining to scaffold erection and removal.

9. When covering scaffold with plastic, tarps or other types of solid material the user must consider all wind and/or snow loading. NextGen recommends that all users consult with an engineer to ensure the proper bracing for the maximum expected wind or snow loads and/or snow loading.

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SAIA—SCAFFOLD AND ACCESS INDUSTRY ASSOCIATION CODE OF SAFE PRACTICES

GIVE TO SCAFFOLD BUILDER AND USER OR POST ON JOB CODE OF SAFE PRACTICES FOR

FRAME SCAFFOLDS, SYSTEM SCAFFOLDS, TUBE AND CLAMP SCAFFOLDS AND ROLLING SCAFFOLDS

DEVELOPED FOR INDUSTRY BY SCAFFOLD INDUSTRY ASSOCIATION, INC.

It shall be the responsibility of all users to read and comply with the following common sense guidelines which are designed to promote safety in the erecting, dismantling and use of scaffolds. These guidelines do not purport to be all-inclusive, nor supplant or replace other additional safety and precautionary measures to cover usual or unusual conditions. If these guidelines in any way conflict with any Federal, State, local or other government statute or regulation, said statute or regulation shall supersede these guidelines and it shall be the responsibility of each user to comply therewith.

General Guidelines

Post these scaffolding safety guidelines in a conspicuous place and be sure that all persons who erect, dismantle or use scaffolding are aware of them.

1. Follow all Federal, State, and local codes, ordinances and regulations pertaining to scaffolding.

2. Survey the jobsite. A survey shall be made of the jobsite for hazards, such as untamped earth fills, ditches, debris, high-tension wires, unguarded openings and other hazardous conditions created by other trades. These conditions should be corrected or avoided as noted in the following sections.

3. Inspect all equipment before using. Never use any equipment that is damaged or defective in any way. Remove it from the jobsite.

4. Scaffolds must be erected in accordance with design and/or manufacturer’s recommendations.

5. Do not erect, dismantle or alter a scaffold unless under the supervision of a qualified person.

6. Do not abuse or misuse the scaffold equipment.

7. Erected scaffolds should be continually inspected

by users to be sure that they are maintained in safe condition. Report any unsafe condition to your supervisor.

8. Never take chances! If in doubt regarding the safety or use of the scaffold, consult your scaffold supplier.

9. Never use equipment for purposes or in ways for which it was not intended.

10. Do not work on scaffolds if your physical condition is such that you feel dizzy or unsteady in any way.

Guidelines for Erection and Use of Scaffolds

1. Scaffold bases must be set on adequate sills or pads to prevent slipping or sinking, and fixed where required. Any part of a building or structure used to support the scaffold, shall be capable of supporting the maximum intended load to be applied.

2. Use adjusting screws or other approved methods, instead of blocking to adjust to uneven grade conditions.

3. Bracing, leveling and plumbing of frame scaffolds:

a.) Plumb and level all scaffolds as the erection proceeds. Do not force frames or braces to fit—level the scaffold until proper fit can easily be made.

b.) Each frame or panel shall be braced by horizontal bracing, cross bracing, diagonal bracing or any combination thereof for securing verticals together laterally. All brace connections shall be made secure, in accordance with the manufacturer’s recommendations.

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SAIA—SCAFFOLD AND ACCESS INDUSTRY ASSOCIATION CODE OF SAFE PRACTICES (CONT’D)

4. Bracing, leveling and plumbing of tube and clamp, and system scaffolds:

a.) Posts shall be erected plumb in all directions, with the first level of runners and bearers positioned as close to the base as feasible. The distance between bearers and runners shall not exceed manufacturer’s recommended procedures.

b.) Plumb, level and tie all scaffolds as erection proceeds.

c.) Fasten all couplers and/or connections securely before assembly of next level.

d.) Vertical and/or horizontal diagonal bracing must be installed according to manufacturer’s recommendations.

5. Tie continuous (running) scaffolds to the wall or structure at each end and at least every 30 feet of length when scaffold height exceeds the maximum allowable free-standing dimension. Begin ties or stabilizers when the scaffold height exceeds that dimension, and repeat at vertical intervals not greater than 26 feet. The top anchor shall be placed no lower than four (4) times the base dimension from the top of the completed scaffold. Anchors must prevent scaffold from tipping into or away from wall or structure. Stabilize circular or irregular scaffolds in such a manner that the completed scaffold is secure and restrained from tipping. When scaffolds are partially- or fully-enclosed or subjected to overturning loads, specific precautions shall be taken to ensure the frequency and accuracy of ties to the wall and structure. Due to increased loads resulting from wind or overturning loads, the scaffolding component to which ties are subjected shall be checked for additional loads.

6. When free-standing scaffold towers exceed four (4) times their minimum base dimension vertically, they must be restrained from tipping. (CAL/OSHA and some government agencies require stricter ratio of 3:1.)

7. Do not erect scaffolds near electrical power lines unless proper precautions are taken. Consult the power service company for advice.

8. A means of access to all platforms shall be provided.

9. Do not use ladders or makeshift. devices on top of scaffolds to increase the height.

10. Provide handrails and mid-rails at each working platform level where open sides and ends exist, and toe boards where required by code.

11. Brackets and cantilevered platforms:

a.) Brackets for system scaffolds shall be installed and used in accordance with manufacturers’ recommendations.

b.) Brackets for frame scaffolds shall be seated correctly, with side bracket parallel to the frames and end brackets at 90 degrees to the frames. Brackets shall not be bent or twisted from normal position. Brackets (except mobile brackets designed to carry materials) are to be used as work platforms only and shall not be used for storage of material or equipment.

c.) Cantilevered platforms shall be designed, installed and used in accordance with manufacturers’ recommendations.

12. All scaffolding components shall be installed and used in accordance with the manufacturers’ recommended procedure. Components shall not be altered in the field. Scaffold frames and their components manufactured by different companies shall not be intermixed, unless the component parts readily fit together and the resulting scaffold’s structural integrity is maintained by the user.

13. Planking:a.) Working platforms shall cover scaffold bearer

as completely as possible. Only scaffold grade wood planking or fabricated planking and decking meeting scaffold use requirements shall be used.

b.) Check each plank prior to use to be sure plank is not warped, damaged, or otherwise unsafe.

c.) Planking shall have at least a 12-inch overlap and extend six (6) inches beyond center of support, or be cleated or restrained at both ends to prevent sliding off supports.

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d.) Solid-sawn lumber, LVL (laminated veneer lumber) or fabricated scaffold planks and platforms (unless cleated or restrained) shall extend over their end supports not less than six (6) inches nor more than 18 inches. This overhang should not be used as a work platform.

14. For putlogs and trusses the following additional guidelines apply:

a.) Do not cantilever or extend putlogs/trusses as side brackets without thorough consideration for loads to be applied.

b.) Putlogs/trusses should be extended at least six (6) inches beyond point of support.

c.) Place recommended bracing between putlogs/trusses when the span of putlog/truss is more than 12 feet.

15. For rolling scaffolds, the following additional guidelines apply:

a.) Riding a rolling scaffold is very hazardous. The Scaffold Industry Association does not recommend, nor encourage this practice. However, if you choose to do so, be sure to follow all State, Federal or other governmental guidelines.

b.) Casters with plain stems shall be attached to the panel or adjustment screw by pins or other suitable means.

c.) No more than 12 inches of the screw jack shall extend between the bottom of the adjusting nut and the top of the caster.

d.) Wheels or casters shall be provided with a locking means to prevent caster rotation and scaffold movement and kept locked.

e.) Joints shall be restrained from separation.

f.) Use horizontal diagonal bracing near the bottom and at 20-foot intervals measured from the rolling surface.

g.) Do not use brackets or other platform extensions without compensating for the overturning effect.

h.) The platform height of a rolling scaffold must not exceed four (4) times the smallest base. Government agencies require a stricter ratio of 3:1).

i.) Cleat or secure all planks.

j.) Secure or remove all materials and equipment from platform before moving.

k.) Do not attempt to move a rolling scaffold without sufficient help. Watch out for holes in floor and overhead obstructions. Stabilize against tipping.

16. Safe use of scaffold:

a.) Prior to use, inspect scaffold to ensure it has not been altered and is in safe working condition.

b.) Erected scaffolds and platforms should be inspected continuously by those using them.

c.) Exercise caution when entering or leaving a work platform.

d.) Do not overload scaffold. Follow manufacturer’s safe working load recommendations.

e.) Do not jump onto planks or platforms.

f.) Do not use ladders or makeshift. devices on top of working platforms to increase the height or provide access from above.

g.) Climb in access areas only and USE BOTH HANDS.

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When Dismantling Scaffolding the Following Additional Guidelines Apply:

1. Check to ensure scaffolding has not been structurally altered in a way which would make it unsafe, and if it has, reconstruct where necessary before commencing with dismantling procedures. This includes all scaffold ties.

2. Visually inspect planks prior to dismantling to be sure they are safe.

3. Consideration must be given as to the effect removal of a component will have on the rest of the scaffold prior to that component’s removal.

4. Do not accumulate excess components or equipment on the level being dismantled.

5. Do not remove ties until scaffold above has been removed (dismantled).

6. Lower dismantled components in an orderly manner. Do not throw off of scaffold.

7. Dismantled equipment should be stockpiled in an orderly manner.

8. Follow erection procedures and user manuals.

These safety guidelines (Codes of Safe Practice) set forth common sense procedures for safely erecting, dismantling and using scaffolding equipment. However, equipment and scaffolding systems differ, and accordingly, reference must always be made to the instructions and procedures of the supplier and/or manufacturer of the equipment.

Since field conditions vary and are beyond the control of the Scaffold Industry Association, safe and proper use of scaffolding is the sole responsibility of the user.

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SCAFFOLD INSPECTION GUIDELINES

During manufacture, InstantLock 2 System Scaffold material goes through a very intensive inspection program. Each part is handled and inspected two (2) times. Items are then randomly selected for non-destructive testing and a final inspection is performed. Further visual inspection is performed as the material is loaded for shipment to any jobsite.

Even with this intensive inspection system, it is still the responsibility of the end-user to ensure each piece of scaffold material installed is free of defects.

Scaffolds are usually built by one craft group and then work is performed on and around the scaffold by many different craft groups. During normal use, it is possible that scaffold components will become damaged. The following are general guidelines to aid the end-user in identifying potential problems with InstantLock 2 System Scaffold material. This list is by no means all-inclusive, and is provided only as a general guide.

All components must be checked every time they are used, prior to installation or removal, for any visible damage, missing or broken welds, deformed or dented parts that may affect the strength of the item, saw marks, welding burn marks, excessive rust or chemical damage.

WARNING: Material must be removed from service any time rust or chemical damage has affected the strength or fit of the material. This is especially critical with the trigger and spring assembly.

End-users should immediately contact their site representative regarding any abnormal issues or concerns.

1. For all items with end connectors, the end connector must be undamaged and the trigger unbroken. Look for missing bolts or nuts that hold in the trigger or spring. Examine the trigger mechanism and ensure the trigger and spring are functioning correctly. Check to ensure the trigger/spring is free of gunnite and other products which could affect the smooth operation of the trigger/

spring. Ensure the fit of the end connector to the vertical post is not excessively loose due to damage to the end connector.

2. Adjustable bearers must be free of any visible damage, missing or broken welds on the end connectors or bent or deformed tubing. The tubing must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the. The locking bolt must be installed and working correctly to prevent movement.

3. Adjustable braces must be free of any visible damage, bent or deformed tubing, missing or broken welds on the end connectors or clamp assemblies. The tubing must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the. The clamp rivet must be examined for wear or bending and the bolt threads must be free of defects. Locking pins must be installed and functional.

4. Beam clamps—rigid and swivel—must be free of any visible damage, saw marks, welding burn marks, large dents, cracks, damaged bolt threads, loose or damaged rivets or other damage. The clamp must be examined for wear, cracking or bending and the bolt threads must be free of defects. Special attention must be given to the radius area of the clamp to ensure there are no cracks in the bend area.

5. Boiler equipment must be free of any visible damage, missing or broken welds. The tubing and beams must be free of any saw marks, welding burn marks, large dents or other damage. Special attention must be placed on the shoring beams and ladders to ensure they are undamaged.

6. Casters must be free of any visible damage. The caster must be round, the pin assembly must be straight, and all bolts and nuts must be present.

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7. Diagonal pin braces must be free of any visible damage, bent or deformed tubing, missing or broken welds on the clamp assemblies. The tubing must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the. The clamp rivet must be examined for wear or bending and the bolt threads must be free of defects.

8. Horizontals must be free of any visible damage, missing or broken welds on the end connectors or bent or deformed tubing. The tubing must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the.

9. Intermediate horizontal adapters must be free of any visible damage, missing or broken welds on the rosettes, bent or deformed rosettes, bent or deformed top plate, missing or bent top pin. The part must also be free from any saw marks, welding burn marks, or other damage which may affect the strength of the.

10. Ladders must be free of any visible damage, missing or broken welds on the rungs, bent or deformed tubing or rungs. The side rails and rungs must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the s.

11. Ladder brackets must be free of any visible damage. The clamp rivet must be examined for wear or bending and the clamp bolt threads must be free of defects.

12. Metal boards must be free of any visible damage, creases in the board surface, bending of the support runners, excessive rust or chemical damage, missing or broken welds on the cleats. Board strength is directly affected by the cleats and the side rails. Ensure the cleats are undamaged and all welds are intact, and ensure the side rails are straight and undamaged.

13. Safety gates must be free of any visible damage, missing or broken welds. The tubing must be free of any saw marks, welding burn marks, large dents or other damage. The clamp rivet must be examined for wear or bending and the clamp bolt threads must be free of defects.

14. Screw jacks and swivel jacks must be checked for proper operation and for damaged threads or nuts. They must be free of any visible damage, bent or deformed tubing, missing or broken welds on the clamp assemblies. The tubing must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the.

15. Side brackets must be free of any visible damage, missing or broken welds on the end connectors or rosettes, bent or deformed tubing. The tubing must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the. Special attention must be placed on inspecting the end connector where it fits into the rosette and the trigger to ensure the bracket fits snugly onto the vertical rosettes, and that there is no visible damage or bending.

16. Stair system parts must be free of any visible damage, missing or broken welds, and all rivets are tight. Stair stringers, bolts and clips must be straight and undamaged. The treads must be able to be properly seated, so when attached each stringer is positioned over the top of one another.

17. Toe boards must be free of any visible damage, saw marks, welding burn marks, large dents or other damage. The toe board tips and locking slide need to be in good working order. The snap buttons must be installed and working correctly

18. Tube and clamp material has been manufactured by many different vendors. When the vendor can be determined, always use their guidelines for inspection and maintenance. The tubing must be free of any visible damage, saw marks, welding burn marks, large dents or other damage. The tube ends must be securely attached to the tubing and must be undamaged. The clamp rivet must be examined for wear or bending and the bolt threads must be free of defects.

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19. Trusses must be free of any visible damage, missing or broken welds on the end connectors or bent or deformed tubing. The tubing must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the.

20. Verticals must be free of any visible damage, missing or broken welds on the rosettes, bent or deformed rosettes, or bent/deformed tubing. The tubing must also be free of any saw marks, welding burn marks, large dents or other damage which may affect the strength of the.

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SCAFFOLD MATERIAL LOADING AND SHIPPING GUIDELINES

These are NextGen's company goals regarding the shipment and receipt of InstantLock 2 scaffold material. Clients are requested to comply with these common sense requirements when they are preparing scaffold shipments for return to NextGen.

1. Upon completion of the project, NextGen requires all scaffold material be properly segregated and racked by individual component. Prior to being released for transport, customers must have completed the following actions to correctly prepare the scaffold material for shipment back to NextGen: a.) Material must be properly segregated into racks

or baskets by size and component.b.) Material must be banded to the rack to ensure it

will not shift. or break loose while in transit.c.) When loading requires any other racks, baskets

or bundled material that are not the same length to be stacked, cribbing must be used between the racks, baskets or material to ensure it is level and will not shift. during transport or unloading.

d.) Never load racks of steel planks or toe boards on the back of the truck, as they can come out easily.

d.) Material must be properly counted and a shipping ticket completed for each truckload.

e.) Advanced copies of shipping tickets must be sent to NextGen.

f.) Shipments must be coordinated in advance with our NextGen warehouse.

g.) Do not schedule material for shipment until all items have been completed.

2. Have proper client authorization request and release paperwork listing material. a.) Computer load calculations are completed for

total weight verification prior to loading material.b.) Complete initial pre-loading diagrams to ensure

how and where material will be placed on truck.c.) Complete all shipment, tractor, trailer and driver

inspection paperwork.d.) You should always have material pulled and

staged prior to truck arrival.e.) For safety reasons, always use a two-man team

when loading scaffold material shipments.

3. Material loading:a.) Do not load trucks early in the morning or late at

night and in instances where there is not enough light to properly and safely see.

b.) Do not let the tractor operator/driver get in the way while you are loading scaffold material.

c.) Require driver to wear hard hat when forklifts are operating during loading and unloading.

4. Prior to loading/releasing incoming or outgoing shipments:a.) Take pictures of all incoming and outgoing

shipments.b.) Use a dry erase board or other means to show

date, time, ticket number, etc.c.) Ensure both the truck and trailer have current

registration tags before loading.d.) Ensure the truck driver has a valid driver’s license

before loading.e.) Trailer and tractor should have good tires (not

bald) on all axles before loading.f.) Ensure the truck driver has all of the required

insurance paperwork before loading.g.) Driver should be observed for any obvious FFD

impairment problems.h.) If all conditions cannot be properly met, do not

load the truck.i.) Once material is loaded onto the trailer, make

sure it is properly secured by the driver.j.) Ensure the correct scaffold material components

and sizes are actually on the trailer.k.) Ensure the driver has been given copies of all

shipping paperwork before he is released.l.) Ensure the driver fully understands where he is

going and when he is expected to arrive.m.) When required, instruct the driver to weigh his

truck at the nearest scales to determine if he is overloaded.

5. When loading requires horizontal racks that are not the same length to be stacked (see picture), the following additional guidelines MUST be met:a.) The rack with the longest horizontals must be

placed on the truck first.b.) The rack with the shortest horizontals must be

placed on top, so that one set of rack feet sit on top of the lower rack’s post.

c.) Cribbing must be placed on top of the horizontals, under the other set of rack feet.

d.) The cribbing must be secured from movement by using cleats, banding or other means.

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e.) The two racks must be banded together to prevent the top rack from dislodging.

f.) If all of the above conditions cannot be properly met, do not load or ship the material.

6. Have an independent (two (2) different people) double-check to verify the following: a.) Ensure the truck is not overweight.b.) Maximum material loaded height above the

ground must not exceed 13.5 feet.c.) Material loaded must not extend beyond the

width of trailer. Notify the receiving organization that the material has departed and is in transit.

a.) Ensure the load will arrive at the designated location during normal working hours/days.

b.) Fax a copy of exactly what material is being shipped to NextGen.

c.) Verify the location is aware that the shipment is en route and that someone will be there to receive and unload it.

7. Charges for return of NextGen material not properly sorted and racked. The goal is for all NextGen material to be returned in the same manner in which it was shipped. Properly prepared InstantLock 2 shipments make it easier, safer, quicker and more accurate for all involved parties in the physical inventory and return process. If for any reason the InstantLock 2 material is not returned as requested, NextGen will take the following corrective actions:

a.) Breaking down of any racks or baskets of material that were improperly loaded.

b.) Properly re-racking as required by our quality assurance program.

c.) Tracking all of the additional man-hours/handling charges associated with re-racking material in order to store the components long term, awaiting future client orders and shipment.

d.) NextGen will invoice the customer for the additional charges incurred with correcting the shipment.

e.) NextGen will also invoice the customer for any fees and/or penalties related to improperly loaded or overloaded return shipments assessed to and paid by NextGen.

8. InstantLock 2 material quantity disputes and final inventory reconciliation. a.) Material shipped from NextGen warehouse

facilities undergoes stringent quantity verification in accordance with NextGen's ISO 9001 program. All outgoing and incoming transactions are subject to two independent verification counts. If needed, a third independent count is performed to reconcile any discrepancies before final shipping or receipt.

b.) All shipments should be verified immediately upon receipt of the material. Any discrepancies must be reported to the NextGen warehouse facility immediately, before any material is utilized. NextGen will have 24 hours after receiving a discrepancy notice to make arrangements for an independent verification, or to submit pertinent information. During this period the material must be segregated, not moved or utilized for erection, allowing NextGen the ability to respond. Material will not be subjected to rent during this period. At the end of this period, if NextGen does not independently verify the counts, the material may be used and the quantities reported by the client will be utilized in the inventory.

c.) Upon receipt of the material at the NextGen warehouse facility, the scaffold material is again subjected to two (2) independent verification

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counts, and if needed a third reconciling count. Any discrepancies between the counts and the quantity reflected on the client-prepared shipping ticket faxed to the NextGen warehouse facility will be reported to the client immediately. The client will have 24 hours after receiving a discrepancy notice to make arrangements for an independent verification. NextGen will segregate and hold the material awaiting the client’s decision. After this period, if the client does not independently verify the counts, the material will be returned to stock and the NextGen counts will be utilized in the inventory.

d.) At the end of the project, all concerned parties will review the final inventory status, which is based on each shipping ticket (inbound and outbound). NextGen will invoice the client for any material shortages or damages which would be included as part of the final closeout invoice.

Always call NextGen in advance of shipping if you have any questions on the above guidelines.

The Deer Park, TX phone number is (832) 479-0779.

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INSTANTLOCK 2 END-USER REPAIR GUIDELINES

REPAIRS AND MAINTENANCE ACTIVITIES THAT ARE AUTHORIZED TO BE PERFORMED IN THE FIELD:

1. Replacement of vertical pins in vertical legs and side brackets.— Must order replacement vertical pins in advance

from NextGen.

2. Replacement of snap buttons in vertical pins, stair stringers or other components.— Must order replacement snap buttons in advance

from NextGen.

3. Replacement of coupling pin snap buttons in vertical legs and side brackets.— Must order replacement vertical pins in advance

from NextGen.

4. Replacement of locking pins in diagonal braces components.— Must order replacement locking pins in advance

from NextGen.

5. Minor bending/straightening of the ladder bracket.— Ladder brackets can become bent in or out

so that they will not correctly fit the ladders. Ladder brackets may be bent straight if the bend required is less than 1/2 inch.

REPAIRS AND MAINTENANCE ACTIVITIES THAT ARE NOT AUTHORIZED TO BE PERFORMED IN THE FIELD:

1. ANY modification to InstantLock 2 System Scaffold.

2. Replacement of trigger assembly in InstantLock 2 components (i.e., trusses, horizontal bars, side brackets, etc.).

3. Replacement of spring assembly in InstantLock 2 components (i.e., trusses, horizontal bars, side brackets, etc.).

4. Replacement of nuts and bolts that hold springs and triggers in InstantLock 2 components.

5. Re-galvanizing InstantLock 2 components that have been corroded or sand blasted.

6. Straightening vertical leg assemblies that have been bent.

7. Shortening vertical leg assemblies by cutting.

8. Straightening horizontal bar assemblies that have been bent.

9. Shortening horizontal bar assemblies by cutting.

10. Any repairs to truss components.

11. Any repairs to metal deck board components.

12. Any repairs to stair stringer components. (With the exception of replacing the snap button in the tread lock down).

13. Any welding to any component.

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INSTANTLOCK 2 ASSEMBLY INSTRUCTIONS

A — Mudsill B — Leveling Jack Maximum Extension, 12" Exposed

ThreadC — Bottom Runner at Bottom Two (2) RosettesD — Diagonal BraceE — Plank BearerF — DeckingG — Midrail at 2nd Set of Rosettes from Bearer

H — Handrail at 3rd Set of Rosettes from BearerJ — Access LadderK — Ladder BracketsL — Safety GateM — Toe Boards on Open Sides

H

L

A

B

C

D

EF

G

J

M

K

instantlock 2 system scaffold component ... - nextgen

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